Factory Workshop Manual
Make
Dodge
Model
Caravan Fwd
Engine and year
V6-3.8L VIN L (1999)
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Date
1st January 2018
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams
Remote Keyless Entry (RKE) Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Page 7
Keyless Entry Module: Adjustments
The content of this article reflects the changes called out by TSB 26-09-99.
PROGRAMMING RKE MODULE
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the
transmitter at the same time. Then press any one of
the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of
the transmitter has been completed and was successful.
7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8.
Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the
ignition OFF. A single chime will sound to verify
that the RKE module will no longer accept additional Vehicle Access Code(s).
9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF
position and verify RKE system operation using each
key fob.
NOTE: Only the two key fob transmitters that have been programmed to the memory seat and
mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will
require programming.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Page 8
Keyless Entry Module: Service and Repair
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer
to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws
holding RKE module to instrument panel.
RKE Module
4. Disconnect wire connector from RKE module.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams
Remote Keyless Entry (RKE) Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 13
Keyless Entry Module: Adjustments
The content of this article reflects the changes called out by TSB 26-09-99.
PROGRAMMING RKE MODULE
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the
transmitter at the same time. Then press any one of
the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of
the transmitter has been completed and was successful.
7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8.
Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the
ignition OFF. A single chime will sound to verify
that the RKE module will no longer accept additional Vehicle Access Code(s).
9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF
position and verify RKE system operation using each
key fob.
NOTE: Only the two key fob transmitters that have been programmed to the memory seat and
mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will
require programming.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 14
Keyless Entry Module: Service and Repair
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer
to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws
holding RKE module to instrument panel.
RKE Module
4. Disconnect wire connector from RKE module.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 18
Power Door Lock Relay: Diagrams
Junction Block
Door Lock Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 19
Door Unlock Relay
Driver Door Unlock Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Technical Service Bulletins > Memory Power Seat - Travel Range
Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range
NO: 08-44-98
GROUP: Electrical
DATE: Dec. 11, 1998
SUBJECT: Memory Power Seat Travel Range
MODELS:
1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand
Cherokee 1996-1998 (ZG) Grand Cherokee (International Market)
DISCUSSION:
The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and
remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in
MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the
motor end, fails to change. The feedback voltage potentiometers vary the position sensing
feedback voltage based on seat position/movement (no movement, no change in position sensing
feedback voltage). The seat motor automatically stops at the soft stop on any subsequent
movement so the motor does not run into a stall condition (end of travel).
The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when
something is stuck under or behind the seat that causes the seat to stop moving). These soft stops
can prevent the seat from being able to have memory positions set over the full range of travel.
Also, positions that were previously programmed to locations beyond an updated soft stop limit will
not be recalled as they are "out of range."
When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed
into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure
to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat
operation.
There are two potential reasons for intermittent memory functioning of the seats. The first
possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned
by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in
the seat's path or a person shifting their body while a power seat motor is in operation.)
The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can
be caused by a poor connection at pin 23 of the P34 connector which is located near the right side
of the steering column. This circuit is used to communicate and control the seat module. This circuit
"locks out" movement when the vehicle is not in park and also causes seat position recall when
used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for
fully seated and clean contacts.
To check and reset the soft stop limits in memory, use the control switches on the side of the seat
to move the seat in one direction to the end of travel, then energize the seat again in the same
direction until it stops and for three additional seconds after it stops. The amount that the seat
moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat
this procedure for each of the directions of movement (one at a time).
NOTE:
IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF
SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM
(AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE
MANUAL).
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation
Seat Heater Control Module: Description and Operation
SYSTEM OPERATION
The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate
the electric seat heater elements. Two modules are used in the vehicle, one for each front seat.
The HSCM for each seat is installed on front portion of each cushion pan. The wire harness
connector is secured by an integral clip to the inside surface of the outboard seat cushion frame.
Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat
cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery
feed, and a ground. The only HSCM output is the feed for the seat heating elements.
The HSCM cannot be repaired and, if faulty or damaged, it must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation > Page 27
Seat Heater Control Module: Testing and Inspection
Before testing the heated seat control module, test the heated seat switch, the heated seat
elements, and the heated seat sensor as described. If testing of the heated seat switch, elements,
and sensor reveals no problems, proceed as follows.
1. Replace the heated seat control module with a known good unit and test the operation of the
heated seats. If OK, discard the faulty heated seat
control module. If not OK, go to Step 2.
2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat
sensor to the heated seat control module. Repair any
short or open circuits as required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation > Page 28
Seat Heater Control Module: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the
vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the
module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5.
Remove module from seat cushion pan.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay >
Component Information > Description and Operation
ABS Main Relay: Description and Operation
ABS FUSES
The ABS system fuse and the ABS pump/motor fuse are located in the Power Distribution Center
(PDC). Refer to the sticker on the inside of the PDC cover for the location of these fuses. The PDC
is located on the driver's side of the engine compartment. The fuse for the amber ABS warning
lamp is located in the fuse junction block under the instrument panel.
If the vehicle is equipped with traction control, the fuse for the traction control switch is located in
the fuse junction block under the instrument panel.
ABS RELAYS
Two relays are used to control the antilock brake system. The two relays are the pump/motor relay
and the system relay. The pump/motor relay and the system relay are located in the CAB. If either
the pump/motor relay or the system relay is diagnosed as not functioning properly, the CAB must
be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications
Electronic Brake Control Module: Specifications
To HCU Mounting Bolts .......................................................................................................................
.................................................. 2 Nm (17 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 36
Controller Antilock Brake (CAB)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 37
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 38
Electronic Brake Control Module: Description and Operation
The Controller Antilock Brake (CAB) is a microprocessor-based device which monitors the ABS
system during normal braking and controls it when the vehicle is in an ABS stop. The CAB is
mounted to the bottom of the HCU. The CAB uses a 25-way electrical connector on the vehicle
wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON
position. The CAB is on the CCD bus.
The primary functions of the (CAB) are to: 1. monitor the antilock brake system for proper
operation. 2. detect wheel locking or wheel slipping tendencies by monitoring the speed of all four
wheels of the vehicle. 3. control fluid modulation to the wheel brakes while the system is in an ABS
mode or the traction control system is activated. 4. store diagnostic information. 5. provide
communication to the DRB scan tool while in diagnostic mode.
The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a
fault, it will turn on the amber ABS warning lamp and disable the antilock braking system. The
normal base braking system will remain operational.
The CAB continuously monitors the speed of each wheel through the signals generated by the
wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking
tendency is detected, the CAB commands the CAB command coils to actuate. The CAB command
coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all
of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until
a locking tendency is no longer present.
The CAB contains a self-diagnostic program that monitors the antilock brake system for system
faults. When a fault is detected, the amber ABS warning lamp is turned on and the fault Diagnostic
Trouble Code (DTC) is then stored in a diagnostic program memory. These DTCs will remain in the
CAB memory even after the ignition has been turned off. The DTCs can be read and cleared from
the CAB memory by a technician using the DRB scan tool. If not cleared with a DRB scan tool, the
fault occurrence and DTC will be automatically cleared from the CAB memory after the identical
fault has not been seen during the next 255 key cycles of vehicle operation or 3,600 miles,
whichever comes first.
CONTROLLER ANTILOCK BRAKE INPUTS
- wheel speed sensors (four)
- stop lamp switch
- ignition switch
- system relay voltage
- ground.
- traction control lamp (if equipped)
- diagnostic communication (CCD)
CONTROLLER ANTILOCK BRAKE OUTPUTS
- body controller communication
- amber ABS warning lamp actuation
- traction control lamp (if equipped)
- diagnostic communication (CCD)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions
Radiator Cooling Fan Motor Relay: Technical Service Bulletins Cooling System - Cooling Fan
Relay Revisions
NUMBER: 26-10-99B
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the cooling fan relay information
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 44
7-1
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 45
7-12
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 46
7-25
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 47
7-25A
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 48
7-25B
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions > Page 49
14-49
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Page 50
Radiator Cooling Fan Motor Relay: Locations
Engine Compartment Connections - Early Build
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Page 51
Engine Compartment Connections - Late Build
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Page 52
Fan Control Module
The SSFR (Solid State Fan Relay) is located on the left front inner frame just behind the radiator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 55
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 56
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 57
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 58
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 59
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 60
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 61
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 62
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 63
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 64
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 65
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 66
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 67
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 68
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 69
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 70
Radiator Cooling Fan Motor Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 71
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 72
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 73
A/C & Heater -- Sheet 8w-42-8
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Diagrams > Page 74
Radiator Cooling Fan Motor Relay: Description and Operation
SOLID STATE FAN RELAY-PCM OUTPUT
The radiator fan runs at a variable speed depending on coolant temperature and A/C system
pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR).
A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR.
Depending upon the amount of pulse on time, the SSFR puts out a proportional voltage to the fan
motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan
motor will be 3.6 volts.
When engine coolant reaches approximately 102 °C (215 °F) the PCM grounds the SSFR relay. If
engine coolant reaches 207 °C (225 °F) the PCM grounds the high speed ground relay and high
speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay and
high speed ground relay when coolant temperature drops to approximately 101 °C (214 °F). When
coolant temperature drops to 101 °C (214 ° F) the fan operates at low speed. The PCM
de-energizes the low speed relay when coolant temperature drops to approximately 93 °C (199 °F).
Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air
conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately
40 psi, the pressure switch opens and the fan operates at low speed.
Fan Control Module
The SSFR relay is located on the left front inner frame just behind the radiator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Component Locations
Blower Motor Relay: Component Locations
Power Distribution Center -- Sheet 8w-10-2
Rear Blower Relay
Rear Blower Motor Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Component Locations > Page 80
This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Component Locations > Page 81
Blower Motor Relay: Connector Locations
Power Distribution Center
Front Blower Motor Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Description and Operation > Front Blower Motor Relay
Blower Motor Relay: Description and Operation Front Blower Motor Relay
Circuit Operation
Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the
HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1.
The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power
Distribution Center (PDC).
The coil side of the relay is energized when the ignition switch is in the RUN position only. Power
for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the
relay
Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit
A22.
Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl
panel.
Ground for the blower motor is controlled through the blower motor resistor and the blower motor
switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Description and Operation > Front Blower Motor Relay > Page 84
Blower Motor Relay: Description and Operation Rear Blower Relay
Circuit Operation
Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp
fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear
blower motor passes through the temperature sensor and one or more resistors, depending on
speed selection.
Two switches operate the rear blower motor by supplying ground; the front control switch and the
rear control switch. The front control switch must be in the ON position for the rear control switch to
operate the rear blower motor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Component Locations
Compressor Clutch Relay: Component Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Component Locations > Page 89
Power Distribution Center -- Sheet 8w-10-2
The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is
located in the engine compartment next to the battery. A label affixed to the underside of the PDC
cover identifies the relays and fuses in the PDC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Component Locations > Page 90
Compressor Clutch Relay: Connector Locations
Power Distribution Center
A/C Compressor Clutch Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 91
Compressor Clutch Relay: Description and Operation
AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT
The PCM operates the air conditioning clutch relay ground circuit, The radiator fan control module
supplies battery power to the solenoid side of the relay. The air conditioning clutch relay will not
energize unless the radiator fan control module energizes. The radiator control module energizes
when the air conditioning or defrost switch is put in the ON position and the low pressure switch,
combination valve, and high pressure switch close.
With the engine operating, the PCM cycles the air conditioning clutch on and off when the A/C
switch closes with the blower motor switch in the On position. When the PCM senses low idle
speeds or wide-open-throttle through the throttle position sensor, it de-energizes the A/C clutch
relay. The relay contacts open, preventing air conditioning clutch engagement.
The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is
located in the engine compartment next to the battery. A label affixed to the underside of the PDC
cover identifies the relays and fuses in the PDC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Cigarette Lighter Relay >
Component Information > Locations
Cigarette Lighter Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Cigarette Lighter Relay >
Component Information > Locations > Page 96
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Cigarette Lighter Relay >
Component Information > Locations > Page 97
Cigarette Lighter Relay: Diagrams
Power Distribution Center
Cigar Lighter/Accessory Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Locations > Page 102
Courtesy Lamp Relay: Diagrams
Junction Block
Courtesy Lamp Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation
Daytime Running Lamp Control Unit: Description and Operation
SYSTEM OPERATION
Combination Flasher / Daytime Running Lamps (DRL) Module
Junction Block Terminal Pins
The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime
running light functions, and has been designed with internal relays to take advantage of low current
switching requirements in the vehicle. It is plugged into the junction block at positions 3 AND 4
where all wiring associated with its operation is terminated. The Junction Block is adjacent to and
left of the steering column of the vehicle.
To gain access to the device, remove the lower steering column cover and knee blocker, refer to
Instrument Panel and Systems.
The combination flasher/DRL may be operated in its hazard warning mode either with or without
the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL
mode, the ignition circuit must be completed to the module.
While the combination flasher portion is idle, there is no current drawn through the module. The
device does not become active in the turn signal or hazard warning modes until a signal ground
circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition
OFF, there is no current drawn through the module.
While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by applying a signal ground input from either the
park brake circuit or the headlamp relay activation circuit.
Typical flash rate for the flasher is 90 flashes per minute.
When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate
will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning
signal mode the flash rate remains at 90 flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of
300 mA., and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
that could draw a maximum of 600 mA. through the multi-function switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 106
Daytime Running Lamp Control Unit: Testing and Inspection
Electronic Combination Flasher Circuit
Electronic Combination Flasher With DRL Circuit
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through
a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This
circuit (L09) is the only power feed to the combination-flasher/ DRL.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 107
Junction Block Terminal Call-Out
Junction Block Terminal Call-Out With DRL
The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal
Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems
with Ignition voltage if the vehicle is so equipped:
- Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically
5 mA of current while active.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 108
Combination Flasher Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 109
Combination Flasher Diagnosis (Part 2 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 110
Combination Flasher Diagnosis With DRL (Part 1 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 111
Combination Flasher Diagnosis With DRL (Part 2 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 112
Combination Flasher Diagnosis With DRL (Part 3 Of 3)
For diagnostic test procedures, refer to Combination Flasher Diagnosis tables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module
> Component Information > Technical Service Bulletins > Recalls for Headlamp Control Module: > NHTSA99V116000 >
May > 99 > Recall 99V116000: Headlamp Module Defect
Headlamp Control Module: Recalls Recall 99V116000: Headlamp Module Defect
Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL"
as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment."
These vehicles do not comply with requirements of FMVSS No. 108.
All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters.
Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on
an agreed upon service date and do not receive the free remedy within a reasonable time should
contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headlamp Control Module: >
NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect
Headlamp Control Module: All Technical Service Bulletins Recall 99V116000: Headlamp Module
Defect
Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL"
as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment."
These vehicles do not comply with requirements of FMVSS No. 108.
All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters.
Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on
an agreed upon service date and do not receive the free remedy within a reasonable time should
contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations
Headlamp Relay: Locations
Battery Negative Cable
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations > Page 132
Power Distribution Center -- Sheet 8w-10-2
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations > Page 133
Headlamp Relay: Diagrams
Power Distribution Center -- Sheet 8w-10-2
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations > Page 134
Power Distribution Center -- Sheet 8w-10-6
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Diagrams
High Beam Relay: Diagrams
Power Distribution Center
High Beam Relay
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Horn Relay: Locations
Battery Negative Cable
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 141
Power Distribution Center -- Sheet 8w-10-2
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 142
Horn Relay: Diagrams
Power Distribution Center
Horn Relay
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Information > Locations > Page 143
Horn Relay: Testing and Inspection
1. Remove horn relay.
Horn Relay
2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance.
If resistance not OK, replace relay 3. Test for continuity between ground and terminal 85 of horn
relay.
a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground
when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as
necessary, refer to Passive Restraints for Driver's Airbag Module Replacement.
4. Using voltmeter, test voltage at:
a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM.
c. If incorrect voltage repair as necessary.
5. Insert a jumper wire between terminal 30 and 87 of the power distribution center.
a. If horn sounds replace relay b. If the horn does not sound, install horn relay and refer to Horn
Test.
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Diagrams
Low Beam Relay: Diagrams
Power Distribution Center
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Diagrams > Page 147
Low Beam Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Parking Lamp Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Page 151
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Page 152
Parking Lamp Relay: Diagrams
Power Distribution Center
Park Lamp Relay
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical
- Wiring Schematics Revisions
Body Control Module: Technical Service Bulletins Electrical - Wiring Schematics Revisions
NUMBER: 26-12-99G
GROUP: Miscellaneous
DATE: December, 1999
THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revisions to the wiring schematics
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- Wiring Schematics Revisions > Page 159
8W-44-5
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- Wiring Schematics Revisions > Page 160
8W-44-7
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- Wiring Schematics Revisions > Page 161
8W-45-7
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- Wiring Schematics Revisions > Page 162
8W-50-2
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- Wiring Schematics Revisions > Page 163
8W-50-5
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical
- Wiring Schematics Revisions > Page 164
8W-50-7
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- Wiring Schematics Revisions > Page 165
8W-80-15
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- Wiring Schematics Revisions > Page 166
8W-90-3
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- Wiring Schematics Revisions > Page 167
8W-90-11
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- Wiring Schematics Revisions > Page 168
Body Control Module: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out
Revisions
NUMBER: 26-04-99
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
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- Wiring Schematics Revisions > Page 169
8N-4
Revision to the Body Control Module connector pin-out
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- Wiring Schematics Revisions > Page 170
8W-80-13
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- Wiring Schematics Revisions > Page 171
Body Control Module: Technical Service Bulletins Body Control Module - Erroneous DTC Set
NO: 18-25-98
GROUP: Vehicle Performance
DATE: Aug. 14, 1998
SUBJECT: Erroneous Body Control Module Diagnostic Trouble Code
MODELS:
1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSAXLE.
DISCUSSION:
During service diagnostic procedures, the Body Control Module (BCM) may indicate an erroneous
"EATX PRNDL NOT RECEIVED" Diagnostic Trouble Code (DTC). If this DTC exists, turn the
ignition to the ON position and determine if each PRNDL indicator in the instrument cluster
becomes boxed (all boxed at the same time) after ten seconds. If all PRNDL indicators do NOT
become boxed at the same time, the DTC is erroneous and the DTC should be cleared, it is not
necessary to replace the BCM.
NOTE:
CHRYSLER HAS NOT RECEIVED ANY REPORTS OF THIS DTC BEING SET BY AN ACTUAL
FAILURE IN THE PRNDL SYSTEM.
POLICY: Information Only
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- Wiring Schematics Revisions > Page 172
Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics
NO: 08-40-98
GROUP: Electrical
DATE: Sept. 25, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED
DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL
VEHICLES.
MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager
DISCUSSION:
During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp
Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head
lamps.
If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at
erasing this erroneous DTC will be unsuccessful.
If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan,
Voyager and Town & Country Body Diagnostic Procedures Manual.**
POLICY: Information Only
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations
Body Control Module: Component Locations
Body Control Module
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Page 175
Junction Block, Body Control Module
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Body Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Instructions > Page 183
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Instructions > Page 186
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Body Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Body Control Module: Connector Views
Body Control Module C1 (A)
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Body Control Module C2 (B)
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Junction Block
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Body Control Module Interconnect
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Body Control Module: Electrical Diagrams
BCM Block Diagram
Wiring Diagrams
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Body Control Module -- Sheet 8w-45-2
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Body Control Module -- Sheet 8w-45-3
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Body Control Module -- Sheet 8w-45-4
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Body Control Module -- Sheet 8w-45-5
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Body Control Module -- Sheet 8w-45-6
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Body Control Module -- Sheet 8w-45-7
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Body Control Module -- Sheet 8w-45-8
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Body Control Module -- Sheet 8w-45-9
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
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Body Control Module: Service Precautions
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
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Body Control Module: Description and Operation Part 1 of 3
INTRODUCTION
Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION
AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger
protection if the vehicle is involved in a front end collision. The system is most effective when used
in conjunction with the seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. This information will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
Functional Operation Whenever the ignition key is turned to the "run" or "start" position, the airbag
control module (ACM) performs a lamp check by turning the AIRBAG warning lamp ON. The lamp
stays lit for 6 to 8 seconds, then goes off. If the lamp remains OFF, it means that the ACM has
checked the system and found it to be free of discernible malfunctions. The airbag system is
monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures in this book to find the cause of any customer complaint regarding the
AIRBAG warning lamp, such as: warning lamp does not come on at all
- warning lamp stays on
BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with
visual and audible information and controls various vehicle functions. To provide and receive
information, the module is interfaced to the vehicle's serial bus communications network (the
Chrysler Collision Detection bus, or CCD bus). This network consists of the powertrain control
module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster
(MIC), the airbag control module (ACM), the compass/mini- trip module and the controller antilock
brake (CAB) module. The BCM is operational when battery power is supplied to the module.
Ignition switch power is needed for ignition switch functions.
The body control module provides the following features: automatic door locks
- battery protection
- CCD radio
- chimes
- compass/mini-trip support
- courtesy lamps
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
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- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid
wearing down the battery if the customer leaves the parklamps or headlamps on for extended
periods of time with the ignition OFF. If the parklamp or headlamp switch remains in the active
position for more than 3 minutes, while the ignition is OFF, the parklamps and or headlamps will be
turned off and the input causing the lamps to be ON will be ignored. Once the 3 minute time-out has
elapsed the BCM will enter sleep mode. Any change in any inputs monitored by the BCM that
brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock), door ajar,
ignition, RKE actuation, etc.).
Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory
power ON) will inhibit the battery protection routine from turning OFF the exterior lamps as
described above.
Battery Protect: "Reading & Glove Box Lamps" This feature provides a battery protection scheme to
avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity
mirrors ON. The BCM provides a ground circuit for these interior lamps. This ground path is
connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters
sleep mode. Once the 15 minutes time-out has expired, any monitored input that brings the BCM
out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central
Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and
vanity mirrors to normal operation (normal operation defined as: "ON" is reading lamp and visor
vanity mirrors ON, or glove box open; "OFF" if reading lamp and visor vanity mirrors OFF, and
glove box closed).
Leaving the keys in the ignition switch, while the ignition is OFF, will not inhibit the battery
protection from turning off these interior lamps as described above. Leaving the ignition switch in
an active position (steering column unlocked, ignition ON or accessory power on) will inhibit the
battery protection routine from turning off these interior lamps as described above.
Shipping Mode By definition, shipping mode is when the IOD fuse is removed from the vehicle. The
BCM receives its primary power feed from the battery via the IOD fuse. The BCM also receives a
back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry,
courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is
reconnected or the ignition switch is turned to the run/start position.
Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which
are controlled by the body controller module (BCM). When the parklamp switch is closed to ground
the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same
parklamp power feed is also wired back into the BCM to provide the power feed for the PWM
circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and
high beam headlamp relays. The position of the hi-beam select switch will determine the mode of
operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and
low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of
operation at a time.
Auto Headlamps On vehicles equipped with the auto headlamp feature, the BCM will control the
exterior lamp operation by monitoring the mode selection switch located in the headlamp control
panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the
Electro-Chromic Rear View mirror. The mirror will determine the appropriate ambient light levels for
turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to
darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see
Headlamp Delay Feature description).
Headlamp Time Delay The headlamp Delay feature keeps the Headlamps on for 60 seconds giving
the driver and passengers security lighting when exiting the vehicle. This feature is only available
on vehicles equipped with RKE. The Headlamp Delay feature is activated by sequentially turning
off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be
turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45
second window is new for the NS body Once the headlamp delay has been activated the
headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the
ignition switch changes states.
CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and
announcement. Warning chimes are provided for dome lamps on, engine temperature lamp,
exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above
15 mph). The warning chime will sound continuously until the condition is removed or the battery
protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for
approximately six seconds or until the seat belt is fastened, The announcement chime will sound
one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar
lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the
vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the
instrument cluster warning lamp diagnostics.
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Body Control Module: Description and Operation Part 2 of 3
COMPASS/MINI-TRIP COMPUTER
The compass/mini-trip computer is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE),
instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information
needed for the traveler functions is received over the CCD bus from the body control module.
If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration.
Setting The Compass The compass/mini-trip module is self-calibrated and requires no adjustment.
The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL
will turn off after the vehicle has gone in three complete circles without stopping, in an area free of
magnetic disturbance.
If the module displays the temperature while the compass is blank or shows a false reading, the
vehicle must be demagnetized. See the service procedure.
If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module
must be replaced.
Compass Magnetic Variance Zones
Setting The Variance Variance is the difference between magnetic north and geographic north. To
determine the variance for the area you are in, refer to the following zone map provided. The
number shown for your area is the variance number for your area. 1. Set the compass/mini-trip
console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5
seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the
variance to 8 and enter the fast calibration mode.
3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP
button to set the zone number. 5. Press the US/M button and resume normal operation,
NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO
THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS.
MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular
position of the gauges, the status of all CCD indicator lamps, the status and dimming of the
mechanical instrument cluster (MIC) over the CCD bus when the ignition is in the "off,, (unlock),
"run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the
ignition is in the "OFF" (unlock), "run", or "start" positions; all other MIC features work only when
ignition is in the "run position. On transition of the ignition from the "OF"' to the "run" position, a bulb
check is performed. This consists of activating all CCD controlled indicator lamps and all VF display
segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is
moved from the PARK position, or if the engine exceeds 450 rpm.
POWER DOOR LOCK SYSTEM When the BCM receives an input for a lock request (door lock
switch, RKE, or door key cylinder switch (only with VTSS)), it will ground the lock-relay coil for a
specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1
second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door
lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The
unlock signal operates in the same fashion as the lock signal. The door Lock switches provide a
variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the
BCM will respond to that command.
Other power Door Lock features: Sliding Door Memory Lock- When the BCM receives an input for
a lock request and a sliding door is open, the BCM will turn on the lock relay
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as described above, and will turn it on again when all sliding doors are closed.NOTE: If the BCM
receives an unlock input before a sliding door is closed this action will cancel the memory lock.
Door Lock Inhibit- When the key is in the ignition and in the off position, and any door except the
rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional.
This protects against locking the vehicle with the keys still in the ignition.
Automatic Door Locks- This feature can be enabled or disabled by using either the DRBIII or
customer programming method. When enabled, all the doors will lock when the vehicle reaches a
speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15
MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH.
RKE (Remote Keyless Entry) Interface- The body control module interfaces with the RKE receiver
via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the
BCM depending on which button on the transmitter was pressed. The BCM controls the door
lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The
RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the
PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the
RKE.
The RKE module can be programmed via the DRBIII or customer programming method. The BCM
will only allow programming mode to be entered when the ignition is in the ON position, the PRNDL
is in park position, and the VTSS (if equipped) is in the disarmed mode.
Programming an RKE Transmitter
Customer Programming Method
NOTE: A VALID, PREVIOUSLY PROGRAMMED TRANSMITTER MUST BE USED.
1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition on, place the transmission
in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3.
Using the previously programmed transmitter, press and hold the unlock button for 4 to 8 seconds.
While still holding the unlock button, press the panic button, then release both buttons. The BCM
will acknowledge that it has grounded the RKE module program enable wire by sounding a single
chime tone.
4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has
accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle
(up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode
sooner, turn the ignition off.
DRB Programming 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition ON,
place the transmission in park, and make sure the vehicle theft security system (if equipped) is in
disarm mode. 3. Select Program RKE" under "Miscellaneous". If the message "BCM is in
Programming Mode" does not appear, exit and select "Program
RKE" again.
4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has
accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle
(up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode
sooner, press "Back Page".
RADIO SYSTEM There are three radio systems available this year that will be on the CCD bus.
They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the
radio remote controls in the steering wheel. They can control volume up/ down, seek up, seek
down and preset station selections. These systems also communicate with the body control
module and will set a specific code if there is a problem with the remote controls.
The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of
the 4 main quarter speakers have a built in amplifier. The I/P and pillar speakers receive their
signals from the quarter speakers. Depending on the manufacture some systems will have a
Front/Rear channel system and others will have a Left/Right channel system. If one of the main
quarter speaker audio circuits experiences a short, the other speakers on that channel will also
shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible
with the DRB, indicating which channel is effected.
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Body Control Module: Description and Operation Part 3 of 3
VEHICLE COMMUNICATION The body system consists of a combination of modules that
communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD
bus, information about the operation of vehicle components and circuits is relayed to the
appropriate module(s). Each module receives the same information about a component or circuit
as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and
the size of the wiring harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system called "bus +" (bus plus)
and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts.
In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded
messages, there is a "voltage divider network". This network consists of some modules with bias
and some with termination. Bias is the part of the voltage divider network that places both bus +
and bus - at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network
and also provides some electromagnetic protection for the bus.
NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF
THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE
OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH
DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE
COMMUNICATIONS.
Any of the following bus failure messages may be displayed. Short to Battery- Either or both of the
bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are
shorted to a 5-volt potential. Short to Ground- Either or both of the bus wires are shorted to ground
or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are
shorted together. No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly
above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules
that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus
Messages Correctly - The DRB cannot communicate over the bus and does not know why.
VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against theft.
The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle
hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the
horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an
engine "no run" feature.
Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's
door, locking the doors with the power lock, and closing the driver's door or locking the doors with
RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator
lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no
monitored systems are activated during this period, the system Will arm. If the hood ajar switch is
seen as closed circuit by the system, the indicator lamp Will remain steadily lit during the arming
process, although the system will still arm.
When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for
about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate
is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override The system will not arm if the doors are locked using the manual lock control (by hand) or if the
locks are actuated by an inside occupant after the door is closed.
When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus
to the powertrain control module that it is not OK to start the engine. The powertrain control module
then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting
down the engine (start and stall condition). The engine will not start until the system is disarmed.
To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but
keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE:
After the doors are closed, locking the doors with RKE will also arm the system.
NOTE: IF THE VTSS INDICATOR LAMP FLASHED, THE SYSTEM IS OPERATIONAL AND
VERIFIED. IF NOT, THERE MAY BE A PROBLEM WITH THE SYSTEM.
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System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is
closed. 1. Rotating the key in liftgate cylinder to unlock/disarm position.
Arming/Disarming- Active arming occurs when the remote keyless entry transmitter is used to lock
the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming
sequence is completed only after all door are closed.
Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with
the key). This disarming also will halt the alarm once it has been activated.
Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle
doors. This disarming also will halt the alarm once it has been activated.
System Self-Test - NOTE: System self-test can be entered only with the DRB.
NOTE: A POWERTRAIN CONTROL MODULE FROM A VEHICLE EQUIPPED WITH A VEHICLE
THEFT SECURITY SYSTEM CANNOT BE USED IN A VEHICLE THAT IS NOT EQUIPPED WITH
A VEHICLE THEFT SECURITY SYSTEM.
If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication
with the powertrain control module possibly has been lost.
WIPER SYSTEM
Front The front wiper system provide the driver with normal wipe (low and high speeds),
intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function
via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the
on position and the ignition is turned OFF the wiper will continue to run until it reaches its park
position.
Other front wiper system features: Speed Sensitive Intermittent Wipe Mode- There are 6 individual
delay times with minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle
speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36
seconds.
Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more
than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided.
Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then
releases it, the wiper will continue to run for 2 additional wipe cycles.
Rear The rear wiper system provides the driver with continuous, intermittent, and wiper after wash
functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the
HVAC control.
DRB III (R) ERROR MESSAGES
Under normal operation, the DRB will display one of only two error messages: - User-Requested
WARM Boot or User- Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the MDS
Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error
message display:
ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD
Boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRB III (R) Does Not Power UP (Blank Screen) If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data
link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A.
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DRB Scan Tool
Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to
compensate for this condition
WARNINGS
Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is
"OFF". Failure to do so could damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair
verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or
symptom condition.
CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE
REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN
WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE
IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB.
REQUIRED TOOLS AND EQUIPMENT
DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires
ohmmeter voltmeter oil pressure gauge (0-300 psi) test light
GLOSSARY OF ACRONYMS
ACM Airbag Control Module
AECM Airbag Electronic Control Module (type of ACM)
ASDM Airbag System Diagnostic Module (type of ACM)
BCM body control module
CAB controller antilock brake
CCD Chrysler Collision Detection (vehicle communications bus)
CMTC
Compass/Mini-Trip Computer (module)
DLC data link connector (previously called "engine diagnostic connector")
DR driver
HVAC heater, ventilation, air condition
MET metric
MIC mechanical instrument cluster
MUX multiplexed
ODO odometer
PASS passenger
PCM powertrain control module
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PDC powertrain distribution center
PTC positive temperature coefficient
RKE remote keyless entry
TCM transmission control module
VF vacuum fluorescent display
VTSS
vehicle theft security system
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Related Diagnostic Procedures
Body Control Module: Symptom Related Diagnostic Procedures
AM/FM Switch Inoperative
SYMPTOM
* AM/FM SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Balance Joystick Inoperative
SYMPTOM
* BALANCE JOYSTICK INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Cassette Error
SYMPTOM
CASSETTE ERROR
POSSIBLE CAUSES
- Cassette Error / Replace radio
CD Eject Switch Inoperative
SYMPTOM
* CD EJECT SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
CD Error
SYMPTOM
CD ERROR
POSSIBLE CAUSES
- Defective radio
Equalizer Inoperative
SYMPTOM
* EQUALIZER INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
External CD Changer (If Equipped)
SYMPTOM
* EXTERNAL CD CHANGER (IF EQUIPPED)
POSSIBLE CAUSES
- Radio/CD cable loose/disconnected
- DIN cable data bus (CAV 1) open
- DIN cable data bus (CAV 3) open
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- DIN cable terminals shorted
- DIN signal wires (CAVS 2, 4, and 5) open
- DIN fused B(+) circuit open
- DIN fused ignition switch output circuit open
- DIN ground circuit open
- DIN metal connectors open
- Radio defective
- Radio input control defective
FF/RW Switch Inoperative
SYMPTOM
* FF/RW SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Hour/Minute Switch Inoperative
SYMPTOM
* HOUR/MINUTE SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
No Sound From All Speakers
SYMPTOM
* NO SOUND FROM ALL SPEAKERS
POSSIBLE CAUSES
- Radio 12V output circuit defective, open
- Radio ground circuit defective, open
- Power relay output circuit defective, open
- Radio 12V output circuit shorted to ground
- Radio choke defective
- Speaker power relay defective, open
- Speaker power relay defective, open
- Junction block defective, open circuit
- Defective radio
- Radio choke output circuit defective, open
- Radio output circuits defective
No Sound From One Speaker
SYMPTOM
* NO SOUND FROM ONE SPEAKER
POSSIBLE CAUSES
- Door or quarter speaker (+) circuit defective, open
- Door or quarter speaker (-) circuit defective, open
- Door or quarter speaker (+) circuit open
- Door or quarter speaker (-) circuit open
- Instrument panel or pillar speaker (+) circuit open
- Instrument panel or pillar speaker (-) circuit open
- Door or quarter speaker defective
- Speaker defective, no response
Pause/Play Switch Inoperative
SYMPTOM
* PAUSE/PLAY SWITCH INOPERATIVE
TEST NOTE
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This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Poor Sound Quality All Speakers
SYMPTOM
* POOR SOUND QUALITY ALL SPEAKERS
POSSIBLE CAUSES
- Antenna connector defective
- Antenna connections defective
- Hood ground defective
- Ground circuit defective, open
- Radio connectors not properly connected
- Ignition / alternator system noise
- Radio defective
Poor Sound Quality From One Speaker
SYMPTOM
* POOR SOUND QUALITY FROM ONE SPEAKER
POSSIBLE CAUSES
- Ground circuit open
- Instrument panel - pillar speaker defective
- Radio choke output circuit open
- Speaker (+) and (-) circuits shorted together
- Inoperative speaker defective
PWR Switch Inoperative
SYMPTOM
* PWR SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Radio Error
SYMPTOM
RADIO ERROR
POSSIBLE CAUSES
- Defective radio
Remote Controls Inoperative
SYMPTOM
* REMOTE CONTROLS INOPERATIVE
POSSIBLE CAUSES
- No response, CCD bus failure
- Radio control harness defective, open
- Radio control MUX circuit shorted
- Remote control switch defective
- MUX control clockspring defective
- Radio control ground circuit to BCM open
- Radio control MUX circuit open
- Radio MUX control circuit defective
- Body Control Module defective
Scan Switch Inoperative
SYMPTOM
* SCAN SWITCH INOPERATIVE
TEST NOTE
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Related Diagnostic Procedures > Page 223
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Seek Switch Inoperative
SYMPTOM
* SEEK SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Set Switch Inoperative
SYMPTOM
* SET SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Shorted Front Channel
SYMPTOM
SHORTED FRONT CHANNEL
POSSIBLE CAUSES
- Left door speaker shorted
- Left front instrument panel speaker shorted
- Right door speaker shorted
- Right front instrument panel speaker shorted
- Right front (-) circuit shorted to ground
- Right front (+) and (-) circuits shorted together
- Right front (+) circuit shorted to ground
- Left front (+) and (-) circuits shorted together
- Left front (+) circuit shorted to ground
- Left front (-) circuit shorted to ground
- Radio output circuits defective
Shorted Left Channel
SYMPTOM
SHORTED LEFT CHANNEL
POSSIBLE CAUSES
- Left door speaker defective, shorted
- Left front instrument panel speaker defective, shorted
- Left quarter speaker shorted
- Left rear (+) and (-) circuits shorted together
- Left rear (+) circuit shorted to ground
- Left rear (-) circuit shorted to ground
- Left rear speaker shorted
- Left front (+) and (-) circuits shorted together
- Left front (+) circuit shorted to ground
- Left front (-) circuit shorted to ground
- Radio output circuits defective
Shorted Rear Channel
SYMPTOM
SHORTED REAR CHANNEL
POSSIBLE CAUSES
- Right rear quarter speaker shorted
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- Left rear (+) and (-) circuits shorted together
- Left rear (+) circuit shorted to ground
- Left rear (-) circuit shorted to ground
- Left rear quarter speaker shorted
- Left rear speaker shorted
- Right rear (+) and (-) circuits shorted together
- Right rear (+) circuit shorted to ground
- Right rear (-) circuit shorted to ground
- Right rear pillar speaker shorted
- Radio output circuits defective
Shorted Right Channel
SYMPTOM
SHORTED RIGHT CHANNEL
POSSIBLE CAUSES
- Right channel speaker shorted
- Right instrument panel speaker defective, shorted
- Right front (+) circuit shorted to ground
- Right front (+) and (-) circuits shorted together
- Right front (-) circuit shorted to ground
- Right pillar speaker shorted
- Right quarter speaker shorted
- Right rear (+) and (-) circuits shorted together
- Right rear (+) circuit shorted to ground
- Right rear (-) circuit shorted to ground
- Radio output circuits defective
Tape Eject Switch Inoperative
SYMPTOM
* TAPE EJECT SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Tune Switch Inoperative
SYMPTOM
* TUNE SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Volume/Time Switch Inoperative
SYMPTOM
* VOL/TIME SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
1-5 Presets Inoperative
SYMPTOM
* 1-5 PRESETS INOPERATIVE
POSSIBLE CAUSES
- Radio function controls inoperative
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Chime Inoperative at All Times
SYMPTOM
* CHIME INOPERATIVE AT ALL TIMES
POSSIBLE CAUSES
- BCM fails chime test
Chime Inoperative With Driver Seat Belt Unfastened
SYMPTOM
* CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED
POSSIBLE CAUSES
- Ground circuit to left seat belt switch connector open
- Left seat belt switch open
- BCM not responding to belt switch
- Body Control Module seat belt switch sense open
- Seat belt switch sense circuit open
Chime Inoperative With Engine Temperature Critical
SYMPTOM
* CHIME INOPERATIVE WITH ENGINE TEMPERATURE CRITICAL
POSSIBLE CAUSES
- BCM - No response to oil pressure
- BCM fails chime test
Chime Inoperative With Exterior Lamps On
SYMPTOM
* CHIME INOPERATIVE WITH EXTERIOR LAMPS ON
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition Switch - key in switch shorted
- BCM - no chime response - head/park lamps ON
- BCM - key in sense shorted default
- BCM - no response to park lamp switch
- Chime inoperative with exterior lamps ON
Chime Inoperative With Key In Ignition & Driver Door Open
SYMPTOM
* CHIME INOPERATIVE WITH KEY IN IGNITION & DRIVER DOOR OPEN
POSSIBLE CAUSES
- Ignition switch ground circuit open
- Key in ignition switch sense circuit open
- Ignition switch - key in switch open
- BCM - no chime to key in ignition
- BCM not responding to key in switch
Chime Inoperative With L or R Turn Signal On For 1 Mile
SYMPTOM
* CHIME INOPERATIVE WITH LEFT OR RIGHT TURN SIGNAL ON FOR 1 MILE
POSSIBLE CAUSES
- Junction block - Left turn signal open
- Junction block - Right turn signal open
- BCM - no response to turn signal
- BCM fails speed test
- Chime - speedometer problem
- Chime inoperative - turn signal on for 1 mile
Chime Inoperative With Low Oil Pressure
SYMPTOM
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* CHIME INOPERATIVE WITH LOW OIL PRESSURE
POSSIBLE CAUSES
- BCM - No response to oil pressure
- BCM fails chime test
Chime Inoperative With the Dome Lamps On
SYMPTOM
* CHIME INOPERATIVE WITH THE DOME LAMPS ON
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition switch - key in switch shorted
- BCM failed - door open & key out default
- BCM - key in switch sense shorted default
Chime Sounds With Driver Door Open & Key Out
SYMPTOM
* CHIME SOUNDS WITH DRIVER DOOR OPEN & KEY OUT
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition switch - key in switch shorted
- BCM - key in switch sense shorted default
- BCM not responding to key out
Chime Sounds With Driver Seat Belt Fastened
SYMPTOM
* CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED
POSSIBLE CAUSES
- Seat belt switch sense circuit shorted to ground
- Left seat belt switch shorted
- BCM - no response to seat belt fastened
- BCM seat belt switch input shorted to ground
Auto Headlamps Will Not Turn Off
SYMPTOM
* AUTO HEADLAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- No response (PCM) - CCD bus failure
- Auto headlamp signal circuit open
- Auto headlamp signal circuit shorted to ground
- Electrochromic mirror defective - sensor stuck ON (default)
- BCM defective - auto headlamp sensor stuck ON
Auto Headlamps Will Not Turn On
SYMPTOM
* AUTO HEADLAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- NO response (BCM) - CCD bus failure
- NO response (PCM) - CCD bus failure
- Auto headlamp signal circuit open
- Electrochromic mirror defective (default)
- BCM defective - auto headlamp sensor
Fog Lamps Will Not Turn Off
SYMPTOM
* FOG LAMPS WILL NOT TURN OFF
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POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Fog lamp switched ground circuit shorted to ground
- Headlamp switch defective - foglamp switched ground
Fog Lamps Will Not Turn On
SYMPTOM
* FOG LAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Fog lamp bulbs open
- Fog lamp relay control circuit open
- Fog lamp relay output circuit open
- Fog lamp relay defective, open
- Multifunction dimmer switch defective (open) default
- Fog lamp switched ground circuit open
- BCM defective - Headlamp relay control
- Multifunction switch defective (fog lamp relay control) default
- Headlamp relay control circuit (foglamps) open
Headlamps Will Not Turn Off
SYMPTOM
* HEADLAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch sense circuit shorted to ground
- Headlamp relay control circuit shorted to ground
- Low beam relay control circuit shorted to ground
- Low beam relay control circuit (QUAD) shorted to ground
- Low beam headlamp relay (QUAD) defective, shorted
- Low beam headlamp relay defective (shorted) by default
- PDC defective (low beam headlamp relay connector shorted)
- Headlamp switch defective - switch sense
- BCM defective (headlamp switch sense function) by default
- BCM defective (low beam relay control shorted) by default
Headlamps Will Not Turn On
SYMPTOM
* HEADLAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch ground circuit open
- Both low beam fuses open
- Fused low beam output circuit open (both lamps inoperative)
- Fused low beam output circuit open (one lamp inoperative)
- Headlamp defective (by default)
- Headlamp fuse open
- Headlamp switch sense circuit open
- Headlamps defective (by default)
- Multifunction switch defective (default)
- Headlamp relay control circuit open
- Low beam relay control circuit (Chrysler) open
- Low beam relay control circuit open
- Low beam headlamp relay defective (by default)
- Low beam relay defective - relay control function
- PDC defective - B(+) circuit at low beam fuse terminal
- Power Distribution Center defective (low beam relay CAV A)
- Power Distribution Center defective (low beam relay CAV B)
- Headlamp switch defective (by default)
- BCM defective - headlamp switch sense function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 228
- BCM defective - headlamp switch sense stuck open
- BCM defective - low beam relay control open
Park Lamps Will Not Turn Off
SYMPTOM
* PARK LAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Park lamp relay control circuit shorted to ground
- Park lamp relay output circuit shorted to voltage
- Park lamp switch sense circuit shorted to ground
- Park lamp relay defective - control shorted (by default)
- Headlamp switch defective - shorted
- BCM defective - park lamp switch sense closed (by default)
Park Lamps Will Not Turn On
SYMPTOM
* PARK LAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch ground circuit open
- Fused park lamp output circuit open
- Park lamp bulb defective (by default)
- Park lamp fuse in PDC open
- Both park lamp fuses open
- Park lamp fuse open
- Park lamp relay control circuit open
- Park lamp relay output circuit open
- Park lamp switch sense circuit open
- Park lamp relay defective (control function)
- PDC defective - other B(+) cavity
- PDC defective - park lamp relay connector, fused B(+)
- Headlamp switch defective - park lamps (by default)
- BCM defective - park lamp switch sense stuck open
- BCM defective - park lamp switch sense function
- BCM defective - parklamp control function (by default)
ABS Warning Lamp
SYMPTOM
* ABS WARNING LAMP
POSSIBLE CAUSES
- BCM connector observable defect
- CAB connector observable defect
- Fused ignition switch output circuit open
- ABS warning lamp defective
- ABS warning lamp driver circuit open
- ABS warning lamp driver circuit shorted to ground
- ABS warning lamp flashing
- BCM defective
- CAB defective
Airbag Warning Lamp
SYMPTOM
* AIRBAG WARNING LAMP
POSSIBLE CAUSES
- Airbag warning lamp failure
All Warning Lamps Out
SYMPTOM
* ALL WARNING LAMPS OUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 229
POSSIBLE CAUSES
- Fused B(+) circuit open
- Fused ignition switch output circuit open
- Ground circuit open
- Information Center defective
Engine Temperature Warning Lamp
SYMPTOM
* ENGINE TEMPERATURE WARNING LAMP
POSSIBLE CAUSES
- Engine temperature lamp staying on
- Temperature lamp not working
- Engine temperature lamp/bulb defective
- Fused ignition switch output circuit open
- Defective BCM
- Engine temperature warning lamp driver circuit open
- Temperature warning lamp driver circuit shorted to ground
- Information Center defective
- Body Control Module defect
- Defective Information Center
High Beam Indicator Lamp
SYMPTOM
* HIGH BEAM INDICATOR LAMP
POSSIBLE CAUSES
- Headlamps inoperative
- Fused right highbeam output circuit open
- Ground circuit open
- High beam indicator bulb defective
- Defective Information Center
Low Oil Pressure Warning Lamp
SYMPTOM
* LOW OIL PRESSURE WARNING LAMP
POSSIBLE CAUSES
- Oil pressure low
- Oil warning lamp/bulb defective
- Oil level low
- Defective oil pressure switch
- Oil pressure switch sense circuit shorted to ground
- Oil pressure switch sense circuit open
- Oil pressure switch defective
- BCM defective
- Defective Information Center
Red Brake Warning Lamp
SYMPTOM
* RED BRAKE WARNING LAMP
POSSIBLE CAUSES
- Park brake pedal problem
- Vehicle equipped antilock brakes
- Brake fluid level low
- Red brake warn lamp/bulb defective
- Ground circuit open
- Brake fluid level switch defective
- Defective ignition switch
- Defective park brake switch
- Red brake warning lamp circuit open
- Red brake warning lamp circuit shorted to ground
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 230
- Information Center faulty
- Ignition switch defective
- Red brake warning lamp driver circuit open
- Red brake warning lamp driver circuit faulty
Service Engine Soon Lamp
SYMPTOM
* SERVICE ENGINE SOON LAMP
POSSIBLE CAUSES
- DTC's are present
- Bulb & socket defective
- Service Engine Soon indicator lamp driver circuit open
- Service Engine Soon indicator lamp circuit shorted to ground
- Defective Information Center circuit board
- Powertrain Control Module defective
Turn Signal Indicator Lamp
SYMPTOM
* TURN SIGNAL INDICATOR LAMP
POSSIBLE CAUSES
- Turn signal lamps inoperative
- Ground circuit open
- Left turn signal circuit open
- Right turn signal circuit open
- Turn signal bulbs defective
- Junction Block defective
- BCM defective
- Information Center defective
Vehicle Theft Alarm Indicator
SYMPTOM
* VEHICLE THEFT ALARM INDICATOR
POSSIBLE CAUSES
- Vehicle theft alarm indicator defective
All Gauges Inoperative
SYMPTOM
* ALL GAUGES NOT OPERATING
POSSIBLE CAUSES
- BCM instrument cluster circuit output defective
- Instrument Cluster PC board defective
- DRB shows ignition unlock closed
- No response - CCD bus instrument cluster
- Body computer odometer failure
- RAM test failure
- ROM test failure
Cluster Illumination
SYMPTOM
* CLUSTER ILLUMINATION
POSSIBLE CAUSES
- No response - CCD bus instrument cluster
- Headlamp switch ground circuit defective
- Inoperative lamp defective
- Headlamp switch defective
- Junction block defective
- Dimmer switch signal circuit open
- Dimmer switch signal circuit shorted to ground
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 231
- Instrument panel lamps driver circuit shorted to ground
- Panel lamps driver circuit open
- Park lamps not lighting
- Instrument Cluster circuit board defective
- BCM dimmer switch signal circuit output faulty
- BCM defective
- BCM defective by default
- Body computer odometer failure
- BCM dimmer switch signal circuit defective
- Illumination panel fuse OK
- Inoperative lamp ground circuit
- RAM test failure
- ROM test failure
Cluster Warning Lamps Odometer and PRNDL Display
SYMPTOM
* CLUSTER WARNING LAMPS ODOMETER AND PRNDL DISPLAY
POSSIBLE CAUSES
- Any one lamp/bulb defective
- Washer fluid level switch sense circuit open
- Washer fluid level switch sense ground circuit open
- Washer fluid level switch sense circuit shorted
- Body computer odometer failure DTC
- No response - CCD bus instrument cluster
- Washer fluid level switch defective
- BCM washer fluid switch sense circuit input defective
- All segments fail to light
- Faulty odometer and PRNDL lamp
- Generator lamp failure
- Instrument cluster printed circuit board defective
Gauges Not Returning to Zero With Key Off
SYMPTOM
* GAUGES NOT GOING TO ZERO WHEN KEY IS TURNED OFF
POSSIBLE CAUSES
- Fused B(+) circuit open
- No response - CCD bus instrument cluster
- Instrument Cluster PC board defective
- Body computer odometer failure
- RAM test failure
- ROM test failure
One Gauge Not Operating Properly
SYMPTOM
* ONE GAUGE OPERATING IMPROPERLY
POSSIBLE CAUSES
- DRB reads active on the bus
- DRB reads no vehicle speed sense signal code
- IOD fuse is loose in junction block
- Speedometer calibration out
- Any one lamp/bulb defective
- DRB reading not matching RPM
- Washer fluid level switch sense circuit open
- Washer fluid level switch sense ground circuit open
- Washer fluid level switch sense circuit shorted
- Washer fluid level switch defective
- Gauge pack defective
- Speedometer/Odometer gauge pack defective
- Tachometer calibration out
- Cooling system condition faulty
- DRB reads coolant temperature sensor code
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 232
- DRB reads engine temperature accurately
- BCM instrument cluster circuit output defective
- Body Control Module defective
- Gauge pack defective
- Instrument Cluster printed circuit board defective
- DRB shows ignition unlock closed
- BCM washer fluid level switch sense circuit input defective
- All segments fail to light
- BCM temperature gauge input defective
- Faulty odometer and PRNDL lamp
- Generator lamp failure
- PCM defective
- Pinion factor failure
Trip and Rest Button(S)
SYMPTOM
* TRIP AND RESET BUTTON(S)
POSSIBLE CAUSES
- Trip & reset button(s) defective
Courtesy Lamps Inoperative W/Dome Lamp Switch
SYMPTOM
* COURTESY LAMPS INOPERATIVE W/DOME LAMP SWITCH
POSSIBLE CAUSES
- Courtesy lamp switch sense circuit open
- Headlamp switch defective - courtesy lamp function open
- BCM defective - courtesy lamp switch sense (by default)
- BCM defective - dome lamp switch function
Courtesy Lamps Inoperative With Any Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH ANY DOOR
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Courtesy lamp relay control circuit open
- Switched courtesy lamp relay control circuit open
- Junction block defective - lamp relay fused B(+) (CAV 87) open
- Courtesy lamp relay defective - coil open
- Junction block defective - lamp relay fused B(+) (CAV 30) open
- Junction block defective - lamp relay fused B(+) (CAV 86) Open
- Headlamp switch defective - open
- BCM defective - lamp relay control function (by default)
- BCM defective - driver door ajar switch status
Courtesy Lamps Inoperative With Driver Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH DRIVER DOOR
POSSIBLE CAUSES
- Driver door ajar switch defective, open
- Driver door ajar switch sense circuit open
- Left front door switch ground strap corroded/damaged
- Body Control Module inoperative, open
Courtesy Lamps Inoperative With Left Sliding Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH LEFT SLIDING DOOR
POSSIBLE CAUSES
- Left sliding door ajar switch sense circuit open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 233
- Left sliding door ajar ground circuit open
- Left sliding door ajar switch defective, open
- BCM defective
Courtesy Lamps Inoperative With Liftgate
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH LIFTGATE
POSSIBLE CAUSES
- Liftgate ground circuit open
- Liftgate ajar switch open - ajar switch disconnected
- Liftgate ajar switch sense circuit open
- BCM defective, open
Courtesy Lamps Inoperative With Passenger Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH PASSENGER DOOR
POSSIBLE CAUSES
- Passenger door ajar switch defective, open
- Passenger door ajar switch sense circuit open
- Right front door switch ground strap corroded/damaged
- Body Control Module inoperative, open
Courtesy Lamps Inoperative With Right Sliding Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH RIGHT SLIDING DOOR
POSSIBLE CAUSES
- Right sliding door ajar switch defective, open
- Right sliding door ajar switch sense circuit open
- Right sliding door ajar ground circuit open
- BCM defective, open
Courtesy Lamps On at All Times
SYMPTOM
* COURTESY LAMPS ON AT ALL TIME
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Courtesy lamp relay output circuit shorted to B(+)
- Courtesy lamp relay control circuit shorted to ground
- Switched courtesy lamp relay control circuit shorted to ground
- Courtesy lamp relay defective - coil shorted
- Headlamp switch shorted
- BCM defective - relay control shorted (by default)
Illuminated Entry Inoperative With Driver Door Key Cylinder
SYMPTOM
* ILLUMINATED ENTRY INOPERATIVE WITH DRIVER DOOR KEY CYLINDER
POSSIBLE CAUSES
- Driver door key switch unlock position stuck
- Driver door key cylinder switch defective
- Driver door key switch sticking
Illuminated Entry Inoperative With RKE Transmitter
SYMPTOM
* ILLUMINATED ENTRY INOPERATIVE WITH RKE TRANSMITTER
POSSIBLE CAUSES
- RKE circuit at BCM defective
- RKE ground circuit open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 234
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- Defective door lock switch
- Defective unlock switch
- RKE module default replacement
- RKE module defective
CMTC Avg MPH/Fuel Economy Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE OR
WRONG
POSSIBLE CAUSES
- No PCM communications
- TPS inoperative
- VSS signal inoperative
CMTC Elapsed Time Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER ELAPSED TIME INOPERATIVE OR WRONG
POSSIBLE CAUSES
- Defective BCM / Indicator lights
CMTC Fails to Respond to Instrument Cluster Dimming
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER
DIMMING
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer
CMTC Trip Odometer Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER TRIP ODOMETER INOPERATIVE OR WRONG
TEST NOTE
This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER AVG MPH OR
FUEL ECONOMY INOPERATIVE/WRONG.
POSSIBLE CAUSES
- No PCM communications
- TPS inoperative
- VSS signal inoperative
Compass/Mini-Trip Computer Displaying OC
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER DISPLAYING OC
POSSIBLE CAUSES
- Open sensor ground circuit
- Ambient Temperature Sensor defective
- Open Ambient Temperature Sensor signal circuit
- Defective Compass/Mini-Trip Module - sensor ground circuit.
Compass/Mini-Trip Computer Displaying SC
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER DISPLAYING SC
POSSIBLE CAUSES
- Defective Ambient Temperature Sensor
- Ambient Temperature Sensor signal circuit shorted to ground
- Compass/Mini-Trip Module default
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 235
Compass/Mini-Trip Computer Segments Fail to Light
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SEGMENTS FAIL TO LIGHT
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer - segments fail to light
Compass/Mini-Trip Computer Shows Failed
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SHOWS FAILED
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer - shows failed
Compass/Mini-Trip Computer Switch Inoperative
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER FAILS TO
RESPOND TO INSTRUMENT CLUSTER DIMMING.
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer
Incorrect Ambient Temperature Readings
SYMPTOM
* INCORRECT AMBIENT TEMPERATURE READINGS
POSSIBLE CAUSES
- Open sensor ground - defective CMTM
- Sensor ground circuit partial short to ground
- Defective Ambient Temperature Sensor/Road test
- Ambient Temperature Sensor signal circuit partial short
- Ambient Temperature Sensor signal circuit shorted
- Defective Compass/Mini-Trip Module
- Defective Compass/Mini-Trip Module sensor ground circuit
Add'l All Doors (Exc Drvr w/RKE) Fail Lck/Unlckfrom Any Switch
SYMPTOM
ADDITIONAL ALL DOORS (EXCEPT DRVR W/RKE) FAIL LCK/UNLCK FROM ANY SWITCH
POSSIBLE CAUSES
- Junction block defective
- Door unlock relay output circuit open
- Door unlock relay output circuit resistance low
Additional All Doors (Exc Driver w/RKE) Fail to Unlock
SYMPTOM
ADDITIONAL ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK
POSSIBLE CAUSES
- Fused B(+) circuit voltage too low at junction block
- Door unlock relay control inoperative at BCM
- Door unlock relay defective
- Door unlock relay coil resistance out of tolerance
- Door unlock relay output circuit shorted to ground
Additional All Doors Fail to Lock and Unlock From Any Switch
SYMPTOM
* ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 236
POSSIBLE CAUSES
- Passenger door switch MUX shorted to battery
- Door lock switch resistance high in unlock position
- Driver door switch MUX circuit shorted to battery
- Liftgate switch MUX shorted to battery
- BCM door lock relay control circuit inoperative
- Liftgate switch MUX at BCM defective
- Door lock relay control ground circuit open
- Door lock relay defective
- Fuse # 26 defective
- Fused B(+) circuit open
- Fused B(+) circuit shorted to ground
- Ground circuit open at door lock relay connector
Additional All Doors Fail to Lock and Unlock From One Switch
SYMPTOM
ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH
POSSIBLE CAUSES
- Door key cylinder switch connector circuit ground circuit open
- Door key cylinder switch defective
- Liftgate key cylinder switch defective
- Liftgate switch MUX shorted to battery
- Door switch MUX circuit to BCM open
- Driver door switch MUX circuit open at BCM connector
- Liftgate switch MUX circuit open at BCM connector
- Liftgate switch MUX circuit to BCM open
- Passenger door switch MUX circuit open at BCM connector
- Passenger door switch MUX circuit to BCM open
- Door lock switch connector ground circuit open
- Door lock switch defective
- Door lock switch MUX circuit open
- Door locks inoperative from key cylinder switch
- Door switch MUX circuit shorted to battery
Additional All Doors Failing to Lock From Any Switch
SYMPTOM
ADDITIONAL ALL DOORS FAILING TO LOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Fused B(+) circuit voltage too low at junction block
- Door lock relay control circuit from BCM fails
- Key - in ignition switch circuit to BCM defective
- Door lock relay does not operate
- Door lock relay coil resistance out of tolerance
- Door lock relay output shorted to ground
- Ignition switch defective
- Key - in ignition switch sense circuit shorted to ground
Additional Driver Door (w/RKE) Failing to Unlock From Any SW
SYMPTOM
ADDITIONAL DRIVER DOOR (W/RKE)FAILING TO UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Driver door unlock relay coil resistance out of tolerance
- Driver door unlock relay defective
- Driver door unlock relay output circuit shorted to ground
- Voltage too low at junction block fused B(+) circuit
Additional One Door Fails to Lock and Unlock From Any Switch
SYMPTOM
ADDITIONAL ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 237
POSSIBLE CAUSES
- RKE equipped door lock fails to lock & unlock
- Door lock motor defective
- Driver unlock relay ground open in junction block
- Door lock relay output circuit open
- Door unlock relay output circuit open
- Driver door unlock relay open
All Doors (Exc Driver w/RKE) Fail Lock/Unlock From Any Switch
SYMPTOM
* ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors (Exc Driver w/RKE) Fail to Unlock
SYMPTOM
* ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK
POSSIBLE CAUSES
- RKE circuit at BCM defective
- RKE ground circuit open
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- Defective door lock switch
- Defective door unlock switch
- RKE module default replacement
- RKE module defective
All Doors Fail to Lock and Unlock From Any Switch
SYMPTOM
* ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Link to body communication bus inoperative
- Defective door lock switch
- Defective unlock switch
All Doors Fail to Lock and Unlock From One Switch
SYMPTOM
* ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors Failing to Lock From Any Switch
SYMPTOM
* ALL DOORS FAILING TO LOCK FROM ANY SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 238
- Defective unlock switch
All Doors Failing to Lock From One Switch
SYMPTOM
* ALL DOORS FAILING TO LOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors Failing to Unlock From One Switch
SYMPTOM
* ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
Automatic Door Locks Do Not Lock Over 15 MPH
SYMPTOM
* AUTOMATIC DOOR LOCKS DO NOT LOCK OVER 15 MPH
POSSIBLE CAUSES
- Link to body communication bus inoperative
- TPS malfunction causes door lock problem
- VSS malfunction causes door lock problem
- Auto door lock not enabled
Doors Lock With Key In Ignition and Left Door Open
SYMPTOM
* DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN
POSSIBLE CAUSES
- Link to body communication bus inoperative
- BCM defective
- BCM sends wrong key - in ignition status
- BCM a connector terminals damaged
- Ignition switch open
- Key - in ignition switch ground circuit open
- Key - in ignition switch sense circuit open
Driver Door (w/RKE) Failing to Unlock From Any Switch
SYMPTOM
* DRIVER DOOR (W/RKE) FAILING TO UNLOCK FROM ANY SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
One Door Fails to Lock and Unlock From Any Switch
SYMPTOM
* ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 239
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
Remote Keyless Entry Problem
SYMPTOM
* RKE PROBLEM
POSSIBLE CAUSES
- Link to body communication bus inoperative
- RKE circuit at BCM defective
- RKE ground circuit open
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- RKE module default replacement
- RKE module defective
Front Wiper Operating Constantly W/Switch In Off Position
SYMPTOM
* FRONT WIPER OPERATING CONSTANTLY W/SWITCH IN OFF POSITION
POSSIBLE CAUSES
- Front wiper ON/OFF relay control circuit shorted to ground
- Defective wiper ON relay/substitute relay
- Defective multifunction switch/voltage
- High/Low wiper relay HI speed output circuit shorted to voltage
- High/Low wiper relay LO speed output circuit shorted to voltage
- Defective BCM - 100 ohms default
Front Wipers Not Parking In Off Position
SYMPTOM
* FRONT WIPERS NOT PARKING IN OFF POSITION
TEST NOTE
This symptom is diagnosed using the test FRONT WIPER PARK SWITCH CIRCUIT OPEN
POSSIBLE CAUSES
- Wiper park switch toggle closed/open
- Open wiper park switch sense circuit
- Defective BCM - wiper park switch
- Defective wiper motor/wiper park switch
Front Wipers Not Working at All
SYMPTOM
* FRONT WIPERS NOT WORKING AT ALL
POSSIBLE CAUSES
- Open wiper on relay control circuit - BCM/wiper relay
- Defective wiper ON relay - BCM/ground
- Front wiper switch MUX circuit shorted to ground
- Open front wiper switch MUX circuit between switch and BCM
- Defective High/Low wiper relay - relay connector
- Defective multifunction switch/front wiper switch
- High/Low wiper relay HI speed output circuit shorted to ground
- High/Low wiper relay LO speed output circuit shorted to ground
- Open ground circuit/lights
- Open High/Low relay LO speed output circuit between High/Low relay and wiper motor
- Open fused ignition switch output circuit/multifunction switch
- Defective Power Distribution Center - relay connector
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Related Diagnostic Procedures > Page 240
- Defective Power Distribution Center - front wiper relay
- Defective Power Distribution Center - wiper ON relay
- Defective Power Distribution Center - wiper relay
- Defective Power Distribution Center - H/L relay
- Defective Power Distribution Center - B(+) circuit.
- Defective wiper motor/harness
- Defective BCM/wiper relay
- Defective BCM/front wiper MUX
- Defective BCM/sensors
- Defective wiper motor ground circuit.
Front Wipers Not Working In High Speed Mode
SYMPTOM FRONT WIPERS NOT WORKING IN HIGH SPEED MODE
POSSIBLE CAUSES
- Open HI/LO wiper relay control circuit
- Defective HI/LO wiper RELAY - Wiper switch
- Open wiper HI/LO relay HI speed output circuit
- Defective multi - FUNCT switch/ ground circuit
- Defective power DIST CNTR-H/L WPR RLY
- Defective wiper Motor/HI speed output circuit
- Open ground circuit/Multi - Function switch
Front Wipers Not Working In Intermittent Mode
SYMPTOM
* FRONT WIPERS NOT WORKING IN INTERMITTENT MODE
POSSIBLE CAUSES
- Defective multifunction switch/positions
- Defective BCM/wiper positions
- Defective multifunction switch/Default
Front Wipers Not Working In Low Speed Mode
SYMPTOM
* FRONT WIPERS NOT WORKING IN LOW SPEED MODE
POSSIBLE CAUSES
- High/Low wiper relay control circuit shorted to ground
- Defective High/Low wiper relay - fused ignition switch
- Open High/Low wiper relay - LO speed output circuit
- Defective wiper motor/LO speed output circuit
Rear Washer Motor Inoperative
SYMPTOM
* REAR WASHER MOTOR INOPERATIVE
POSSIBLE CAUSES
- Open rear washer motor control circuit
- Defective rear washer motor/jumper
- Open fused ignition switch output circuit/voltage
- Defective HVAC Control Module / 3.8 volts
- Defective BCM - washer motor operate
Rear Wiper Not Parking In the Off Position
SYMPTOM
* REAR WIPER NOT PARKING IN THE OFF POSITION
POSSIBLE CAUSES
- Rear wiper motor control circuit shorted to battery
- Defective HVAC Control Module/switch indicator lights
- Defective wiper motor/wiper motor connector
- Defective BCM/rear wiper motor - default
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Related Diagnostic Procedures > Page 241
- Defective BCM/washer motor run
- Defective BCM/cycle on default
- Defective BCM/rear wiper switch voltage
- Defective rear wiper motor/test light
Rear Wiper Not Working at All
SYMPTOM
* REAR WIPER NOT WORKING AT ALL
POSSIBLE CAUSES
- Open rear wiper motor control circuit
- Open rear wiper switch MUX circuit
- Open ground circuit/rear wiper motor
- Open fused ignition switch output circuit/fuse # 6
- Open fused ignition switch output circuit/fuse # 8
- Shorted fused ignition switch output circuit/fuse # 6
- Defective rear wiper motor/motor control
- Defective HVAC Control Module/default
- Defective HVAC Control Module/rear wiper switch MUX
- Defective BCM/rear wiper switch MUX
- Defective BCM/rear wiper motor
- Defective HVAC Control Module/21-Way connector
Rear Wiper Not Working In the Intermittent Mode
SYMPTOM
* REAR WIPER NOT WORKING IN THE INTERMITTENT MODE
POSSIBLE CAUSES
- Defective rear wiper motor/intermittent switch
- Defective HVAC Control Module/indicator light
- Defective HVAC Control Module/rear wiper switch
- Defective BCM/test light default
Rear Wiper/Wash Working Continuously
SYMPTOM
* REAR WIPER/WASH WORKING CONTINUOUSLY
POSSIBLE CAUSES
- Rear wiper motor control circuit shorted to battery
- Defective wiper motor/wiper motor connector
- Defective BCM/rear wiper motor - default
- Defective BCM/washer motor run
- Defective BCM/rear wiper switch voltage
Wiper/Wash Function Not Working Properly
SYMPTOM
* WIPER/WASH FUNCTION NOT WORKING PROPERLY
POSSIBLE CAUSES
- Defective washer motor/washer pump control
- Operate wipers
- Open washer pump control circuit
- Defective multifunction switch/washer pump control
- Open fused ignition switch output circuit
- Defective junction block/BCM
- Defective junction block/block connector
- Defective BCM/junction block
- Defective BCM/stalk switch
- Fused ignition switch output circuit shorted to ground
- Open washer pump control circuit/multifunction switch
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Related Diagnostic Procedures > Page 242
Body Control Module: Component Tests and General Diagnostics
Six-Step Troubleshooting Procedure
Diagnosis of the body system is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
Road Testing A Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE
REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN
WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE
IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB.
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Body Control Module: Scan Tool Testing and Procedures
Under normal operation, the DRB will display one of only two error messages: - User-Requested
WARM Boot or User-Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the MDS
Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error
message display:
ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD
Boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRB III (R) Does Not Power up (Blank Screen) If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data
link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A.
DRB Scan Tool
Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to
compensate for this condition
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Body Control Module: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove lower steering column cover and
knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control
Module (BCM)
Body Control Module - Location
4. Remove bolts holding Junction Block to dash panel mounting bracket. 5. Remove Junction Block
from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide
Body Control Module downward to disengage guide studs on Junction Block from channels on
BCM mounting bracket. 8. Remove Body Control Module from Junction Block.
INSTALLATION
For installation, reverse the above procedures.
REMOVAL AND INSTALLATION
Refer to Instrument Panel and Systems, Body Control Module Replacement.
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Body Control Module: Tools and Equipment
DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires
ohmmeter voltmeter oil pressure gauge (0-300 psi) test light
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Locations
Powertrain Control Module: Locations
Power Distribution Center & Powertrain Control Module (PCM)
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Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Powertrain Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Powertrain Control Module: Connector Views
Powertrain Control Module C1
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Powertrain Control Module C2
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Powertrain Control Module: Description and Operation
OPERATION
Powertrain Control Module
The ignition system is regulated by the Powertrain Control Module (PCM). The PCM supplies
battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM also controls
ground circuit for the ignition coil. By switching the ground path for the coil on and off, the PCM
adjusts ignition timing to meet changing engine operating conditions.
During the crank-start period the PCM advances ignition timing a set amount. During engine
operation, the amount of spark advance provided by the PCM is determined by the following input
factors: available manifold vacuum
- barometric pressure
- engine coolant temperature
- engine RPM
- throttle position
The PCM also regulates the fuel injection system. Refer to the Fuel Injection.
The speed control electronic control circuitry is integrated into the Powertrain Control Module
(PCM). The PCM is located in the engine compartment. The PCM speed control functions are
monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the
PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a
DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be
replaced if faulty.
USE THE DRB SCAN TOOL TO REPROGRAM THE NEW PCM WITH THE VEHICLES
ORIGINAL IDENTIFICATION NUMBER (OIN) AND THE VEHICLES ORIGINAL MILEAGE. IF
THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
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Powertrain Control Module: Service and Repair
REMOVAL
1. Disconnect both cables from battery, negative cable first.
NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after
disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection
Power Distribution Center Retaining Screws
2. Remove 2 screws holding Power Distribution Center (PDC) to bracket.
Battery Heat Shield
3. Remove heat shield from battery.
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Battery Clamp
4. Remove nut and clamp holding battery to battery tray. 5. Remove battery from vehicle.
PDC Rear Bracket
6. Rotate PDC toward center of vehicle to remove from rear bracket. 7. Pull PDC rearward to
remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM).
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PCM 40-way Connectors
8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM. Remove both
way connectors.
PCM Removal/Installation
9. Remove 3 screws holding PCM to fender.
10. Remove PCM from vehicle.
INSTALLATION
1. Connect 2 40-Way electrical connectors to PCM. 2. Install PCM. Tighten mounting screws. 3.
Install PDC bracket. 4. Install battery.
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Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Battery Negative Cable
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Component Information > Locations > Page 278
Power Distribution Center -- Sheet 8w-10-2
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Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Component Information > Diagrams > Diagram Information and Instructions > Page 295
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Component Information > Diagrams > Diagram Information and Instructions > Page 296
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Component Information > Diagrams > Diagram Information and Instructions > Page 297
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 298
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Component Information > Diagrams > Diagram Information and Instructions > Page 299
Automatic Shut Down (ASD) Relay: Connector Views
Power Distribution Center
Automatic Shut Down Relay
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Component Information > Diagrams > Page 300
Automatic Shut Down (ASD) Relay: Description and Operation
Power Distribution Center
DESCRIPTION
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and
fuses in the PDC.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02
Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM
monitors the crankshaft position sensor and camshaft position sensor signals to determine engine
speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor
and camshaft position sensor signals when the ignition switch is in the Run position, it will
de-energize the ASD relay.
AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT
OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt
signal at this input indicates to the PCM that the ASD has been activated. This input is used only to
sense that the ASD relay is energized.
When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC).
AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT
The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic
ignition coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and
contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss
bar in the PDC and the relay. The fuse is located in the PDC.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2
Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the
On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position
sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not
receive the crankshaft position sensor and camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the ASD relay.
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Component Information > Diagrams > Page 301
Power Distribution Center
The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies
the relays and fuses in the PDC.
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Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
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Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 304
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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Automatic Shut Down (ASD) Relay: Service and Repair
The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover
has a label showing relay and fuse location.
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Fuel Pump Relay: Locations
Battery Negative Cable
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Power Distribution Center -- Sheet 8w-10-2
The fuel pump relay is located in the PDC.
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Fuel Pump Relay: Diagrams
Power Distribution Center
Fuel Pump Relay
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Fuel Pump Relay: Description and Operation
FUEL PUMP RELAY-PCM OUTPUT
The fuel pump relay supplies battery voltage to the fuel pump. The fuel pump relay power circuit
contains a 9 amp fuse. The fuse is located in the PDC.
The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the
relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position.
When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft
position sensor does not detect engine rotation, the PCM de-energizes the relay after
approximately one second.
The fuel pump relay is located in the PDC. A label affixed to the underside of the PDC cover
identifies the relays and fuses in the PDC.
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Fuel Pump Relay: Testing and Inspection
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
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terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Battery Negative Cable
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Component Information > Locations > Page 318
Power Distribution Center -- Sheet 8w-10-2
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Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Component Information > Diagrams > Diagram Information and Instructions > Page 323
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Component Information > Diagrams > Diagram Information and Instructions > Page 325
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Component Information > Diagrams > Diagram Information and Instructions > Page 328
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Component Information > Diagrams > Diagram Information and Instructions > Page 329
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Component Information > Diagrams > Diagram Information and Instructions > Page 330
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Component Information > Diagrams > Diagram Information and Instructions > Page 332
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 333
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Component Information > Diagrams > Diagram Information and Instructions > Page 334
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Component Information > Diagrams > Diagram Information and Instructions > Page 335
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Component Information > Diagrams > Diagram Information and Instructions > Page 336
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 338
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Component Information > Diagrams > Diagram Information and Instructions > Page 339
Automatic Shut Down (ASD) Relay: Connector Views
Power Distribution Center
Automatic Shut Down Relay
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Component Information > Diagrams > Page 340
Automatic Shut Down (ASD) Relay: Description and Operation
Power Distribution Center
DESCRIPTION
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and
fuses in the PDC.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02
Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM
monitors the crankshaft position sensor and camshaft position sensor signals to determine engine
speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor
and camshaft position sensor signals when the ignition switch is in the Run position, it will
de-energize the ASD relay.
AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT
OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt
signal at this input indicates to the PCM that the ASD has been activated. This input is used only to
sense that the ASD relay is energized.
When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC).
AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT
The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic
ignition coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and
contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss
bar in the PDC and the relay. The fuse is located in the PDC.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2
Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the
On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position
sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not
receive the crankshaft position sensor and camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the ASD relay.
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Component Information > Diagrams > Page 341
Power Distribution Center
The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies
the relays and fuses in the PDC.
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Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
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Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 344
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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Component Information > Testing and Inspection > Page 345
Automatic Shut Down (ASD) Relay: Service and Repair
The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover
has a label showing relay and fuse location.
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
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Component Information > Locations > Page 350
Air Bag Control Module: Diagrams
Airbag Control Module C1
Airbag Control Module C2
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Air Bag Control Module: Description and Operation
SYSTEM OPERATION
The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The
ACM monitors the system to determine the system readiness. The ACM contains on-board
diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs.
The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or
serious injury, caused by a frontal impact of the vehicle.
The impact sensor provides verification of the direction and severity of the impact. One impact
sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a
bracket, just forward of the center console. The impact sensor is an accelerometer that senses
deceleration. The deceleration pulses are sent to a microprocessor which contains a decision
algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor
sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor
is calibrated for the specific vehicle and reacts to the severity and direction of the impact.
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Air Bag Control Module: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
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Component Information > Locations > Page 353
Air Bag Control Module: Service and Repair
Negative Battery Cable
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS.
REMOVAL
1. Remove forward lower console from instrument panel, refer to Instrument Panel and Systems for
proper procedures.
Heat Duct
2. Remove screw holding lower heat duct to instrument panel support. 3. Remove heat duct from
instrument panel.
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Instrument Panel Supports
4. Remove two bolts holding top of right support to instrument panel. 5. Remove two bolts holding
bottom of right support to floor pan. 6. Separate right instrument panel support from vehicle.
ACM Connectors
7. Disconnect two connectors from ACM.
8. Remove four bolts holding the ACM bracket assembly to floor.
INSTALLATION
WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET
THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD
NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET
INSTALLED.
CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM.
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For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with
the proper screws and tighten to 8.5 to 11.9 Nm (75 to 105 in. lbs.) torque. Do not connect battery
negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures.
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Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Battery Negative Cable
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Component Information > Locations > Page 360
Power Distribution Center -- Sheet 8w-10-2
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Component Information > Locations > Page 361
Starter Relay: Diagrams
Power Distribution Center
Engine Starter Motor Relay
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Component Information > Locations > Page 362
Starter Relay: Description and Operation
STARTER RELAY-PCM OUTPUT
Double Start Override is a feature that prevents the starter from operating if the engine is already
running. This feature is accomplished with software only. There was no hardware added because
of this feature. To incorporate the unique feature of Double Start Override, it was necessary to use
the PCM (software) to control the starter circuit. To use the PCM it was necessary to separate the
starter relay coil ground from the park neutral switch. The starter relay ground is now controlled
through Pin 60 of the PCM. This allows the PCM to interrupt the ground circuit if other inputs tell it
that the engine is turning. If the starter system is operating properly, it can be assumed that the
override protection is also working.
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Starter Relay: Testing and Inspection
WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK
POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED.
Starter Relay
Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine
compartment. Refer to the PDC label for relay identification and location. Remove the starter relay
from the PDC as described to perform the following tests: 1. A relay in the de-energized position
should have continuity between terminals 87A and 30, and no continuity between terminals 87 and
30. If OK,
go to Step 2. If not OK, replace the faulty relay.
2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +-5 Ohms. If OK, go to
Step 3. If not OK, replace the faulty relay 3. Connect a battery B+ lead to terminals 86 and a
ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity
between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to
Relay Circuit Test procedure. If not OK, replace the faulty relay.
Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage
and should be hot at all times. If OK, go to Step 2. If not OK, repair
the open circuit to the PDC fuse as required.
2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized
position, but is not used for this application. Go to Step
3.
3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the
energized position. This terminal supplies battery
voltage to the starter solenoid field coils. There should be continuity between the cavity for relay
terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the
open circuit to the starter solenoid as required.
4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position.
On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test.
Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start
position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5.
If not OK with an automatic transmission, check for an open or short circuit to the ignition switch
and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test
procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch
pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position
Switch Test procedure.
5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with an
automatic transmission, it is grounded through the
park/neutral position switch only when the gearshift selector lever is in the Park or Neutral
positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity
to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an
open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK,
see the Park/Neutral Position Switch Test procedure. If not OK with a manual transmission, repair
the circuit to ground as required.
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Control Module: Specifications
Sixty-Way Connector 35 in.lb
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Transmission Control Module
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Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Connector Pin Identification
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Control Module: Description and Operation
AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT
The electronic automatic transaxle control module and the PCM supply information to each other
through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the
information when adjusting the fuel and ignition strategy.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 392
Control Module: Service and Repair
OVERVIEW
Do not interchange Transmission Control Modules with previous year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed: Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
REMOVAL
Fig. 27
1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then
disconnect the 60 way connector on Transmission
Control Module.
Fig. 28
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Page 393
Fig. 29
2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28
and 29).
INSTALLATION
1. To install, reverse removal procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 397
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 398
Transmission Control System Relay: Diagrams
Power Distribution Center
Transmission Control Relay (EATX)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 399
Transmission Control System Relay: Description and Operation
TRANSMISSION CONTROL RELAY
The transmission control relay is located in the Power Distribution Center (PDC) on the left side of
the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is
used to supply power to the solenoid pack when the transmission is in normal operating mode.
When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in
mode. After a controller reset (ignition key turned to the run position or after cranking engine), the
TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for
no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack
pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify
that the voltage is greater than 3 volts.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 404
Heated Glass Element Relay: Diagrams
Junction Block
Rear Window Defogger Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations
Front Windshield Wiper
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations > Page 409
Wiper Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations
Wiper Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Page 413
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Page 414
Wiper Relay: Diagrams
Power Distribution Center
Wiper High/Low Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Page 415
Wiper On/Off Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Arm/Disarm Switch, Antitheft > Component Information > Diagrams
Arm/Disarm Switch: Diagrams
Driver Door Arm/Disarm Switch
Passenger Door Arm/Disarm Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door
Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch
Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Open the front door.
Front Door Ajar Switch
3. Remove the screw holding the door ajar switch to the door B-pillar. 4. Remove the door ajar
switch from the B-pillar. 5. Disconnect the wire connector from the back of the ajar switch and
remove the switch.
INSTALLATION
For installation reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door
Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch > Page
425
Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Release the sliding door latch and allow
back of the door to pop open.
Sliding Door Ajar Switch
3. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar
switch from quarter panel opening. 4. Disconnect the wire connector from the back of the ajar
switch. 5. Remove the sliding door ajar switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood
Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood.
Negative Battery Cable
2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry
trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire
connector and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock
Cylinder Switch > Component Information > Service and Repair
Lock Cylinder Switch: Service and Repair
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel and sound
pad. 3. Close the door window. 4. Disconnect the door key cylinder switch wire connector from the
door harness and wiring clip from the impact beam. 5. Remove the front door outside handle from
the door.
Door Lock Cylinder Switch
6. Disengage the lock tab holding switch to the back of the lock cylinder. 7. Remove the switch
from the door handle.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Remote Switch, Audio - Stereo > Component Information > Description and Operation
Remote Switch: Description and Operation
SYSTEM OPERATION
Remote Radio Switches
Remote Radio Switch Operational View
A remote radio control switch option is available on LXI models sold in North America with the
AM/FM/ cassette/5-band graphic equalizer with CD changer control feature (RBN sales code), or
the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two
rocker-type switches are mounted on the back (instrument panel side) of the steering wheel
spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset
station advance functions. The switch on the right spoke is the volume control switch and has
volume up, and volume down functions.
These switches are resistor multiplexed units that are hard-wired to the Body Control Module
(BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision
Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data
bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For
more information on the operation of the remote radio switch controls, refer to the owner's manual
in the vehicle glove box.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 435
Remote Switch: Testing and Inspection
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system
capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the
steering wheel.
Remote Radio Switches
3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test
table.
REMOTE RADIO SWITCH TEST Switch position = Resistance Volume Up = 7320 Ohms Volume
Down = 1210 Ohms Seek Up = 4530 Ohms Seek Down = 2050 Ohms Pre-set station advance =
10 Ohms
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right"/Left remote radio switch orientation is with the steering wheel installed, and driver in
drivers seat.
4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check
for continuity between the ground circuit cavity of the switch wire harness connector and a good
ground. There should be continuity If OK,
go to Step 6. If not OK, repair the open circuit as required.
6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check
for continuity between the radio control circuit
cavity of the remote radio switch wire harness connector and a good ground. There should be no
continuity If OK, go to Step 7. If not OK, repair the short circuit as required.
7. Check for continuity between the radio control circuit cavities of the remote radio switch wire
harness connector and the BCM wire harness
connector. There should be continuity If OK, refer to the proper Diagnostic Procedures to test the
BCM and the CCD data bus. If not OK, repair the open circuit as required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 436
Remote Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system
capacitor to discharge before further service. 2. From the underside of the steering wheel, remove
the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the airbag
module away from the steering wheel far enough to access the wire harness connectors on the
back of the airbag module. 4. Unplug the airbag module and horn switch wire harness connectors
from the back of the airbag module. 5. Remove the driver side airbag module from the vehicle. 6.
Remove the steering wheel from the steering column. 7. Unplug the wire harness connector from
the remote radio switch(s). 8. Remove three screws securing steering wheel rear cover. 9. Remove
the remote radio switch from the steering wheel by depressing tabs on each side of switch.
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right/left remote radio switch orientation is with the steering wheel installed, and driver in
drivers seat.
INSTALLATION
For installation, reverse the above procedure. The switches can only be installed one way. Be
careful to index them correctly before pressing them into place.
Tighten the airbag module mounting screws to 10.2 Nm (90 in. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Diagrams
Trunk/Liftgate Sensor/Switch (For Alarm): Diagrams
Hood Ajar Switch
Liftgate Arm/Disarm Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger)
Switch
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate latch from the vehicle.
3. Disconnect the wire connector from the liftgate ajar switch.
Liftgate Ajar Switch
4. Remove the screw holding the ajar switch to the liftgate latch and remove the switch.
INSTALLATION
For installation, Reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger)
Switch > Page 442
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Key Cylinder Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate trim panel. 3.
Disconnect the liftgate key cylinder switch wire connector from the liftgate harness and clip from the
liftgate inner panel. 4. Remove the liftgate outside handle.
Liftgate Cylinder Lock Switch
5. Disconnect the lock tab holding the switch to the back of lock cylinder and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood.
Negative Battery Cable
2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry
trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire
connector and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Diagrams
Power Door Lock Switch: Diagrams
Driver Door Lock Switch
Passenger Door Lock Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Diagrams > Page 451
Power Door Lock Switch: Testing and Inspection
1. Remove door lock/power window switch bezel assembly from door. Refer to Power Door Lock
Switch Replacement. 2. Disconnect wire connector from back of door lock switch. 3. Depress
switch to LOCK position.
Door Lock Switch
Door Lock Switch Test
4. Using an ohmmeter, test switch resistance between Pins 2 and 3. Refer to Door Lock Switch
Test. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. If
resistance values are not within the parameters shown replace the door lock switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Diagrams > Page 452
Power Door Lock Switch: Service and Repair
The Power Door Lock Switch is the only serviceable part on the power door lock / window switch
bezel.The window switches, window lock - out, and power vent window switch is serviced with the
bezel.
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the negative battery cable. 2. Open left door, remove screw cover near
inside door release handle. 3. Remove two screws to door lock / window switch bezel. One under
the screw cover removed in previous step and one to the rear of the front door
vent opening.
4. Pull out and up on bezel to release from door trim panel. 5. Disconnect door lock switch
connector. 6. Remove two door lock switch retaining screws and remove switch from vehicle.
INSTALLATION
1. For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Testing and Inspection
Power Mirror Switch: Testing and Inspection
1. Remove power mirror switch. Refer to Instrument Panel and Systems for Replacement
Procedures. 2. Disconnect wiring harness at switch connector.
Mirror Switch Test
3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in
the table are not obtained, replace the switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Service and Repair > Power Mirror Switch
Power Mirror Switch: Service and Repair Power Mirror Switch
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to
Instrument Cluster Bezel Replacement.
Power Mirror Switch
3. Disconnect wire connector from back of power mirror switch. 4. Disengage lock tabs above and
below the mirror switch. 5. Pull power mirror switch from headlamp switch bezel. The power mirror
switch bezel is mounted to the bottom of the instrument cluster bezel. 6. Remove power mirror
switch.
INSTALLATION
For installation, reverse the above procedures.
REMOVAL AND INSTALLATION
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Service and Repair > Power Mirror Switch > Page 458
Power Mirror/Window Switch
Refer to Instrument Panel and Systems for service procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Service and Repair > Power Mirror Switch > Page 459
Power Mirror Switch: Service and Repair Power Mirror Switch Lamp
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to
Instrument Cluster Bezel Replacement. 3. Remove instrument cluster bezel.
Power Mirror Switch Lamp
4. Rotate bulb socket counterclockwise one quarter turn. 5. Pull bulb socket from back of power
mirror switch.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection
Power Seat Switch: Testing and Inspection
1. Remove seat switch from seat. Refer to Seat Switch Replacement.
Seat Switch Test
2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the
switch positions, replace switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Page 463
Power Seat Switch: Service and Repair
REMOVAL AND INSTALLATION
Negative Battery Cable
1. Disconnect and isolate the battery negative cable.
Bucket See Cushion Side Cover Remove/Install
2. Remove seat cushion side cover.
Set Switch Wire Connector
3. Disconnect the wire connector to the seat switch and remove side cover from vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation
Seat Heater Switch: Description and Operation
SYSTEM OPERATION
The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The
two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective
Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both
the driver and the front seat passenger can select a preferred seat heating mode.
Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat
that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If
either switch or LED is faulty, the switch must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation > Page 467
Seat Heater Switch: Testing and Inspection
1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion
side cover. Check for continuity between the ground circuit cavity of the switch wire harness
connector
and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit
as required.
3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery
voltage at the fused ignition switch output circuit
cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position,
disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open
circuit as required.
4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK,
replace the faulty switch.
5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty
switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation > Page 468
Seat Heater Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755),
gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect
wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out
switch from rear of switch bezel. 5. Remove switch from bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams
Liftgate Ajar Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Service and Repair
Brake Fluid Level Sensor/Switch: Service and Repair
The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for
replacement of the brake fluid level switch.
REMOVAL
Fluid Level Sensor Electrical Connection
1. Remove wiring harness connector from brake fluid reservoir level switch.
Master Cylinder Brake Fluid Level Switch
2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With
retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master
cylinder brake fluid reservoir.
INSTALLATION
1. Insert the brake fluid level switch into brake fluid reservoir. Be sure switch is pushed in until
retaining tabs lock it to the brake fluid reservoir. 2. Connect the vehicle wiring harness connector to
the brake fluid level switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations
Traction Control Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Harness Side
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Harness Side > Page 481
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Page 482
Traction Control Switch: Testing and Inspection
Traction Control Switch Connector
1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading
between pins.
Traction Control Switch Continuity
Switch Position = Continuity between Actuated = Pins 1 and 2 Illumination = Pins 1 and 3
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Page 483
Traction Control Switch: Service and Repair
Battery Negative Cable
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the over steering column bezel. 3.
Remove the two screws attaching traction control switch to the bezel.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications
Wheel Speed Sensor: Electrical Specifications
Allowable Resistance 900 - 1300 ohms
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications > Page 488
Wheel Speed Sensor: Mechanical Specifications
Front Rear
Minimum Clearance 0.014 in 0.016 in
Maximum Clearance 0.047 in 0.047 in
To Axle Or Steering Knuckle Mounting Bolt 105 in.lb 105 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Front Wheel Speed Sensors
Front Wheel Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 491
Rear Wheel Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Front
Wheel Speed Sensor: Diagrams Front
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Front > Page 494
Wheel Speed Sensor: Diagrams Rear
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Page 495
Wheel Speed Sensor: Description and Operation
Front Wheel Speed Sensor
Rear Wheel Speed Sensor (FWD)
One Wheel Speed Sensor (WSS) and one tone wheel are located at each front and rear wheel.
Each front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel
is part of the outboard constant velocity joint. The rear wheel speed sensor on rear disc brake
applications is mounted to the rear disc brake adapter. The rear tone wheel is an integral part of
the rear wheel hub and bearing.
The wheel speed sensor sends a small AC signal to the CAB. This signal is generated by magnetic
induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic wheel
speed sensor. The CAB converts the AC signal into a digital signal. If a wheel locking tendency is
detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s)
from locking.
Correct ABS operation is dependent on accurate wheel speed signals. The vehicle's tires and
wheels all must be the same size and type to generate accurate signals. Variations in tire and
wheel size can produce inaccurate wheel speed signals.
Improper speed sensor-to-tone wheel clearance can cause erratic speed sensor signals. The
speed sensor air gap is not adjustable, but should be checked when applicable. Wheel speed
sensor-to-tone wheel clearance specifications can be found in Specifications.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Page 496
Wheel Speed Sensor: Testing and Inspection
Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following
possible causes. missing, chipped, or broken teeth
- contact with the wheel speed sensor
- wheel speed sensor to tone wheel alignment
- wheel speed sensor to tone wheel clearance
- excessive tone wheel runout
- tone wheel loose on its mounting surface
If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt
should be made to replace just the tone wheel.
If a rear tone wheel is found to need replacement on front-wheel-drive models, the tone wheel is
serviceable separately. If a rear tone wheel is found to need replacement on all-wheel-drive
models, the drive shaft must be replaced. No attempt should be made to replace just the tone
wheel.
If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before
replacing the wheel speed sensor or tone wheel.
Check the gap between the speed sensor head and the tone wheel to ensure it is within
specifications.
Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. If tone wheel
runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and
bearing. Replace as necessary.
Tone wheels are pressed onto their mounting surfaces and should not rotate independently from
the mounting surface. Replacement of the front driveshaft or rear hub and bearing is necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement
Front
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
Front Speed Sensor Cable Channel Bracket
3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame
rail.
CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not
to damage pins on connector.
Speed Sensor Cable To Vehicle Wiring Harness
4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect
speed sensor cable from vehicle wiring harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 499
Front Wheel Speed Sensor Attaching Bolt
5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor
head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON
SENSOR HEAD. Use a
hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free.
Front Wheel Speed Sensor Cable Routing
7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front
wheel speed sensor assembly from the vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as
shown may result in contact with moving parts and/or over extension of cables, resulting in an open
circuit.
1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure
speed sensor cable connector is fully seated and
locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut
tower.
CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the
channel bracket.
2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching
the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4.
Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to
steering knuckle on the rearward side of the
stabilizer bar link.
5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor
attaching bolt to a torque of 12 Nm (105 inch lbs.) 6. Check the air gap between the face of the
wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (.047 inches).
7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of
the base and ABS brake systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 500
Rear
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
CAUTION: When unplugging speed sensor cable from vehicle wiring harness, be careful not to
damage pins on the electrical connectors. Also inspect connectors for any signs of previous
damage.
Rear Speed Sensor Cable Connection To Vehicle Wiring Harness
3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from
vehicle wiring harness.
CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during removal of the speed sensor cable.
Speed Sensor Cable Attachment To Brake Flex Hose
4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 501
Right Rear Speed Sensor Cable Routing
5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the
axle flange, the brake tube clip and the routing clip
from the track bar bracket on the axle.
Rear Speed Sensor Routing Brackets And Clips
6. Remove the 2 rear wheel speed sensor cable/brake tube routing clips. Then unclip the speed
sensor cable from the routing clips on rear brake tube.
CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor
head in an attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the
sensor from side to side until free.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 502
Rear Wheel Speed Sensor Attaching Bolts
7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not
come loose, do not use pliers. Tap with screw driver
and hammer.
8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed
sensor assembly from vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as
shown may result in contact with moving parts and/or over extension of cables, resulting in an open
circuit.
1. Install wheel speed sensor head. Note the plastic anti rotation pin must be fully seated prior to
installing the attaching bolt.
CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must
be fully seated into the bearing flange.
Rear Wheel Speed Sensor Attaching Bolts
2. Install the wheel speed sensor head to bearing flange attaching bolt. Tighten the attaching bolt to
a torque 12 Nm (105 inch lbs.) 3. Check the air gap between the face of the wheel speed sensor
and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inches).
4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle.
The rear wheel speed sensor cable should be routed
under the rear brake tube.
CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during installation of the wheel speed
sensor cable.
5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear
speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 503
CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed
sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the
vehicle wiring harness, do not force the connectors together. If the connectors are forced together,
damage to the connectors will occur.
7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable
connector is fully seated and locked into vehicle wiring
harness connector.
8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into
the body hole. 9. Install the tire and wheel assembly on vehicle.
10. Road test vehicle to ensure proper operation of the base and ABS braking systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 504
Wheel Speed Sensor: Service and Repair Tone Wheel Replacement
This procedure is for the removal of the ABS rear tone wheel from the rear hub and bearing on
front wheel drive vehicles. Vehicles equipped with AWD have a tone wheel mounted on the
driveshaft outer constant velocity joint and it is serviced with the driveshaft.
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and
tire assembly. 3. Remove rear brake drum from the hub/bearing assembly.
Rear Wheel Speed Sensor
4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage
to the speed sensor during removal and
installation of the hub/bearing assembly.
Rear Hub/Bearing Mounting Bolts
5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 505
Removing Rear Hub/Bearing From Axle
6. Remove the hub/bearing assembly from the rear axle and brake support plate.
Tone Wheel Removal From Hub/Bearing Assembly
7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage
by the vise jaws. Mount the hub/bearing assembly
in a vise. Using Puller, Special Tool C-4693 installed as shown remove the tone wheel from the
hub/bearing assembly.
INSTALL
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 506
Installing Tone Wheel On Hub/Bearing Assembly
1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3.
Position Driver, Special Tool 6908-1 with undercut
side facing up on top of the tone wheel.
Correctly Installed Tone Wheel
2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3.
Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the
rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the
rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts
into hub/ bearing assembly. Tighten the 4 bolts in a
criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto
flange of rear axle.
6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.) 7. Install the rear
wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and
tighten to a torque of 12 Nm (105
inch lbs.).
8. Check the air gap between the face of the wheel speed sensor and the top surface of the tone
wheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inches).
9. Install the brake drum onto the rear hub/bearing assembly.
10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust
the rear brakes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Temperature Sensor 7 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 512
Coolant Temperature Sensor/Switch (For Computer): Locations
Engine Coolant Temperature Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 513
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 514
Coolant Temperature Sensor/Switch (For Computer): Service Precautions
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT
TEMPERATURE (ECT) SENSOR.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 515
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT
The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40°
F to 265° F).
The engine coolant temperature sensor provides an input voltage to the PCM. As coolant
temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM.
When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The engine coolant sensor is also used for cooling fan control.
Engine Coolant Temperature Sensor
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 516
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Engine Coolant Temperature Sensor
1. With the key off, disconnect wire harness connector from coolant temperature sensor.
Engine Coolant Temperature Sensor
2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter
should read as follows:
a. ECT STET at normal operating temperature around 200°F should read approximately 700 to
1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately
7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater
than 1 ohm, repair the wire harness as necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 517
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT
TEMPERATURE SENSOR.
REMOVAL
1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant
sensor electrical connector. 3. Remove coolant sensor.
INSTALLATION
1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector
to sensor. 3. Fill cooling system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Temperature Sender Unit 60 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations
Speed Control Switches
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations > Page 525
Cruise Control Switch: Description and Operation
DESCRIPTION
There are two separate switch pods that operate the speed control system.
OPERATION
The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON,
OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual
for more information on speed control switch functions and setting procedures.
The individual switches cannot be repaired. If one switch fails, the entire switch module must be
replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations > Page 526
Cruise Control Switch: Testing and Inspection
Refer to the appropriate Powertrain Diagnostics for switch test values.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations > Page 527
Cruise Control Switch: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove
airbag/horn pad from steering wheel, refer to Airbags and Seat Belts/Airbags for proper
procedures. 4. Disconnect wire connector from horn switch, airbag, and speed control switches.
Speed Control Switches
5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control
switch from airbag/horn pad.
INSTALLATION
Reverse the preceding operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent
Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 536
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service
Bulletins: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 542
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Vehicle Speed Sensor/Transducer - Cruise Control: > 23-11-00 > Mar > 00 > Roof Panel - Wavy or has Depressions
Roof Rack Frame: All Technical Service Bulletins Roof Panel - Wavy or has Depressions
BULLETIN NUMBER: 23-11-00
GROUP: Body
DATE: Mar.24, 2000
SUBJECT: Roof Panel Wavy Or Has Depressions
MODELS: 1996 - 2000 (NS) Town & County/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-28-96, DATED MAY 3,
1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1996
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
OVERVIEW: This bulletin involves applying heat to the roof panel to remove depression(s). This
Repair Procedure is not intended to be used to correct any type of impact/damage caused dents.
SYMPTOM/CONDITION: The roof panel surface exhibits waviness or depression(s) near the front
of the character features or skid strip for roof rack equipped vehicles. Typically the shape of the
depression or waviness will be elliptical or along a line across the vehicle. The depression(s) will go
away on their own as the vehicle is exposed to higher ambient temperatures and sun load.
DIAGNOSIS: While standing in front of the vehicle, visually inspect the roof panel, if any
depression(s) or waviness is seen in one or both areas shown in Figure 1, perform the following
Repair Procedure only if the customer is unwilling to wait for higher ambient temperatures to
remove the depression(s).
EQUIPMENT REQUIRED. Heat Gun such as Pentastar Service Equipment (PSE) W-PH12OO
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Vehicle Speed Sensor/Transducer - Cruise Control: > 23-11-00 > Mar > 00 > Roof Panel - Wavy or has Depressions > Page
548
Figure 1
1. Refer to Figure 1 and apply heat to of the areas indicated for one depression at a time. The heat
gun should be set for approximately 500° F (260° C). Keep the gun moving constantly to avoid
scorching the paint. Avoid applying heat directly to the roof rack skid strips if so equipped.
2. Continue applying heat evenly until the depression is removed, the roof panel will usually "pop"
when the depression removal is complete.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Vehicle Speed Sensor/Transducer - Cruise Control: > 23-11-00 > Mar > 00 > Roof Panel - Wavy or has Depressions > Page
554
Figure 1
1. Refer to Figure 1 and apply heat to of the areas indicated for one depression at a time. The heat
gun should be set for approximately 500° F (260° C). Keep the gun moving constantly to avoid
scorching the paint. Avoid applying heat directly to the roof rack skid strips if so equipped.
2. Continue applying heat evenly until the depression is removed, the roof panel will usually "pop"
when the depression removal is complete.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Page 555
Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation
OPERATION
The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM.
The PCM determines acceleration rates. The speed control software in the PCM uses vehicle
speed and acceleration to control to the set speed.
Vehicles with a 3 speed automatic or manual transmission have a Vehicle Speed Sensor (VSS)
mounted to an adapter near the transmission output shaft. The sensor is driven through the
adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to
determine vehicle speed and to maintain speed control set speed. Refer to the appropriate
Powertrain Diagnostic Procedures for diagnosis and testing of this component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Page 556
Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection
For diagnosis and testing of the Vehicle Speed Signal (VSS), refer to the appropriate Powertrain
Diagnostic Procedures. Also refer to the DRB scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Specifications
Oil Pressure Sender: Specifications
Oil Pressure Gauge Sending Unit 60 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Specifications > Page 561
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Specifications > Page 562
Oil Pressure Sender: Diagrams
Engine Oil Pressure Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Description and Operation
Air Conditioning Switch: Description and Operation
AIR CONDITIONING SWITCH SENSE-PCM INPUT
When the air conditioning or defrost switch is put in the ON position and the low pressure switch,
combination valve, and high pressure switch close, the PCM receives an A/C input. After receiving
this input, the PCM activates the A/C compressor clutch by grounding the A/C clutch relay. The
PCM also adjusts idle speed to a scheduled RPM to compensate for increased engine load.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Service and Repair > Rear Heater - A/C Switch Lamp Replacement
Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Lamp Replacement
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel HVAC Control. Refer
to Radio Bezel and HVAC Control Replacement.
Rear Heater - A/C Switch Lamp Bulb
3. Rotate bulb socket counterclockwise one quarter. 4. Pull bulb socket from switch.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Service and Repair > Rear Heater - A/C Switch Lamp Replacement > Page 569
Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Replacement
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel and HVAC Control.
Rear Heater - A/C Switch
3. Remove screw holding rear heater-A/C switch to radio bezel HVAC Control. 4. Disengage hook
holding bottom of switch to radio bezel HVAC Control. 5. Remove switch from radio bezel HVAC
Control.
INSTALLATION
For instrument, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
Ambient Temperature Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 573
Ambient Temperature Sensor / Switch HVAC: Diagrams
Ambient Temperature Sensor
Ambient Temperature Sensor (Sensor Side)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 574
Ambient Temperature Sensor / Switch HVAC: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Raise and support vehicle on safety stands.
3. From behind front bumper fascia, remove screw holding sensor to radiator closure panel. 4.
Remove sensor from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Description and Operation
Blower Motor Switch: Description and Operation
SYSTEM OPERATION
Rear Blower Speed Switch The rear blower speed switch controls the rear blower with the choice
of low and high speeds. when the switch is on it allows the blower speed switch located on the rear
headliner to control rear blower speed. This switch will override the rear headliner blower switch.
For operation instructions refer to the Owner's Manual. The rear blower speed switch is serviced
separately from the A/C control module. For service procedures, refer to Instrument Panel And
Gauges.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Description and Operation
Evaporator Temperature Sensor / Switch: Description and Operation
SYSTEM OPERATION
Evaporator Probe The Evaporator probe is located on the HVAC. The probe prevents evaporator
freeze-up by signaling the Powertrain Control Module to cycle the compressor ON and OFF. The
probe monitors the temperature of the refrigerant after expansion.
The evaporator probe is inserted into the evaporator between the coils. The probe is a sealed unit
and cannot be adjusted or repaired. It must be replaced if found defective.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics
Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Temperature
Diagnostics
The evaporator probe can be tested by using the INTERMITTENT LED to display the actual
temperature the sensor is reading. The HVAC control module can only display temperatures from 1
to 99 degrees. To read the temperature, perform the following:
- Set Blower motor to any speed other than OFF
- Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared. To clear
the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then,
press and hold the intermittent wipe button for 5 seconds.
- Run Diagnostics (Depress REAR WIPER and REAR WASH)
- When Diagnostics is complete, Cycle to Level 4.
Display Sequence is as follows:
- REAR WIPER LED will display the Level
- INTERMITTENT LED will display ten's digit
- Short Pause
- INTERMITTENT LED will display the one 5 digit.
The HVAC control module will continue to cycle the Level and then Temperature until the level is
changed or Calibration Diagnostics and Cooldown test is exited.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 583
Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Test
Evaporator Probe: Resistance Vs. Temperature Chart
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 584
Resistance Measurement Table
The evaporator probe is located in the unit housing and placed in the evaporator fins. The probe
prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when
evaporator temperature drops below freeze point. It cycles ON when the evaporator temperature
rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The
tube is inserted between the evaporator fins in the heater-A/C unit housing.
A malfunctioning evaporator probe may show symptoms such as:
- Ice blocking the airflow, or frost exiting out of the outlets and vents
- No air conditioning operation
- No power to the compressor clutch during A/C selection
The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) during testing.
1. Place the vehicle in a location out of direct sunlight and allow the vehicle to come to ambient
temperature (the engine can remain warm). 2. With the engine OFF, lower the windows, and turn
on the interior blower (with the system in Fresh Air mode). 3. Place a thermometer in one of the
Instrument Panel outlets, and a second one in the intake duct (plenum area by the windshield
wipers). 4. Allow the blower to run until both temperatures readings are within 2° F of one another
and constant. 5. Remove the electrical connector from the evaporator probe and measure the
resistance of the probe with a multimeter.
6. Consult the temperature/resistance chart and table to determine whether the resistance is within
specification.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 585
If the measurements fall outside the specifications, replace the evaporator probe.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Testing and Inspection > Page 586
Evaporator Temperature Sensor / Switch: Service and Repair
REMOVAL
1. Remove the glove box. Refer to Instrument Panel and Systems.
Evaporator Probe Connector
2. Disconnect the evaporator probe connector.
Evaporator Probe Grommet
3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing.
Evaporator Probe
4. Remove evaporator probe from evaporator.
INSTALLATION
For installation, reverse the above procedures. Three holes are provided in evaporator for probe
location. When reinstalling probe, use a different hole than original one. If a new evaporator is
installed, insert the probe in the uppermost hole provided.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications
Refrigerant Pressure Sensor / Switch: Specifications
Low psi control opens < 29.4 psi High psi control opens > 450 psi
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 590
A/C Pressure Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 591
Refrigerant Pressure Sensor / Switch: Description and Operation
SYSTEM OPERATION
A/C Pressure Transducer
A/C Pressure Transducer
The A/C Pressure Transducer monitors the refrigerant gas pressure on the high side of the system.
The transducer is located on the liquid line. The pressure transducer turns off the voltage to the
compressor clutch coil when refrigerant gas pressure drops to levels that could damage the
compressor. The transducer also is used to adjust condenser fan speeds and will turn off
compressor at high refrigerant pressures. The pressure transducer is a sealed factory calibrated
unit. It must be replaced if defective. O-ring replacement is required whenever the pressure
transducer is serviced. Be sure to use the O-ring specified for the transducer.
AIR CONDITIONING PRESSURE TRANSDUCER-PCM INPUT
The Powertrain Control Module (PCM) monitors the A/C compressor discharge (high side)
pressure through the air conditioning pressure transducer. The transducer supplies an input to the
PCM. The PCM engages the A/C compressor clutch if pressure is sufficient for A/C system
operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 592
Refrigerant Pressure Sensor / Switch: Testing and Inspection
The work area temperature must not be below 10° C (50° F) to test the compressor clutch circuit.
Before starting to test the transducer ensure that the wire connector is clean of corrosion and
connected properly.
1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Install
scan tool (DRB):
- Go to main menu
- Select stand alone scan tool (DRB)
- Select refer to the proper year diagnostics
- Select climate control
- Select sensor display
- Select A/C high side volts
For A/C system to operate a voltage between 0.451 (Low Pressure Cutout) to 4.519 (High
Pressure Cutout is required. Voltages outside this range indicate a low or high pressure condition
and will not allow the compressor to cycle.
A/C Pressure Transducer Voltage
Refer to the A/C Pressure Transducer Voltage table for the appropriate condition(s):
1. Connect a tachometer and manifold gauge set. 2. Set control to A/C, RECIRC, and PANEL,
temperature lever on full cool and blower on high. 3. Start engine and hold at 1000 rpm with A/C
clutch engaged. 4. Engine should be warmed up with doors and windows closed. 5. Insert a
thermometer in the left center A/C outlet and operate the engine for five minutes. The A/C clutch
may cycle depending on ambient
conditions.
6. With the A/C clutch engaged, compare the discharge air temperature to the A/C Performance
Temperatures table.
A/C Performance Temperature Chart
7. If the discharge air temperature fails to meet the specifications in the performance temperature
chart. Refer to the Refrigerant Service Procedures
for further diagnosis.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 593
Refrigerant Pressure Sensor / Switch: Service and Repair
REMOVAL
1. Disconnect the wire connector at the pressure transducer.
A/C Pressure Transducer Removal
2. Using an open end wrench, remove the transducer from the liquid line.
INSTALLATION
1. Replace transducer O-ring. 2. For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
Brake Switch (Typical)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 605
Brake Light Switch: Diagrams
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 606
Brake Light Switch: Description and Operation
DESCRIPTION
The switch is mounted on the brake pedal mounting bracket under the instrument panel.
OPERATION
Vehicles equipped with the speed control option use a dual function stop lamp switch. The PCM
monitors the state of the dual function stop lamp switch. Refer to the stop lamp switch service and
adjustment procedures.
BRAKE SWITCH-PCM INPUT
When the brake switch is activated, the PCM receives an input indicating that the brakes are being
applied. After receiving this input the PCM maintains idle speed to a scheduled RPM through
control of the idle air control motor. The brake switch is mounted on the brake pedal support
bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 607
Brake Light Switch: Testing and Inspection
Stop Lamp Wiring
1. Remove the stop lamp switch refer to Stop Switch Replacement. Disconnect connector from
stop lamp switch. Using an ohmmeter, switch
continuity may be checked as follows:
2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch
plunger depressed, there should be continuity:
- Between Pin 1 and Pin 2.
- Between Pin 3 and Pin 4.
4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 608
Brake Light Switch: Adjustments
1. Remove stop lamp switch from its bracket by rotating it approximately 30 in a counter-clockwise
direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch
firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until
it has ratcheted out to
its fully extended position.
4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake
pedal as far down as possible. Then while keeping
the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on
switch with slot at top of square hole in mounting bracket. When switch is fully installed in the
square hole of the bracket, rotate switch clockwise approximately 30 to lock the switch into the
bracket.
Stop Light Switch Location In Vehicle
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can
result.
5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake
pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the
correct position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 609
Brake Light Switch: Service and Repair
REMOVAL
Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a
counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from
bracket. Disconnect wiring harness connector.
INSTALLATION
Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until
the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure.
Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch
with the plunger facing forward in car. There is an index key on the switch that mates with the
bracket slot at the top of the square hole. Align key and push switch into square hole in bracket
while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise
approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is
released. Pull back on the pedal to assure correct adjustment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 618
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 619
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 620
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 621
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 622
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 623
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 629
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 630
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 631
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 632
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 633
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 634
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch
> Component Information > Service and Repair
Glove Box Lamp Switch: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable.
Glove Box Lamp And Switch
2. Open glove box door. 3. Using a trim stick (special tool #C-4755), lightly pry glove box
lamp/switch from instrument panel. 4. Disengage wire connector from glove box lamp and switch.
5. Remove glove box lamp and switch.
Glove Box Lamp
6. Remove lamp.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch
> Component Information > Service and Repair > Page 638
REMOVAL
1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument
panel.
Glove Box Lamp And Switch
3. Disconnect wire connector from glove box lamp. 4. Remove glove box lamp from vehicle.
INSTALLATION
1. Position glove box lamp in vehicle. 2. Connect wire connector from glove box lamp. 3. Position
glove box lamp in instrument panel. 4. Press lamp into instrument panel until fully
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Diagrams
Multi-Function Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Diagrams > Page 642
Hazard Warning Switch: Testing and Inspection
To test turn signal, headlamp beam select and optical horn portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Turn Signal - Multi-Function Switch Pin Numbers
2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the
above image for proper pin numbers and Turn
Signal Multi-Function Switch Test table.
TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between
Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Diagrams > Page 643
Hazard Warning Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR PROPER AND SAFE SERVICE
PROCEDURES.
REMOVAL 1. Release hood latch and open hood.
Battery Negative Cable
2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column
shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For installation, reverse the above procedures. Verify switch operation by placing
the control stalk in either the right or left position and turning the steering wheel to ensure the
automatic cancellation of the switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams
Headlamp Switch: Diagrams
Headlamp Switch C1
Headlamp Switch C2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 647
Headlamp Switch: Testing and Inspection
Headlamp Switch Continuity
Rheostat Continuity
Headlamp Switch Connectors (Switch Side)
Using a Digital Multimeter equipped with a diode test, perform the Headlamp Switch Continuity test
and the Rheostat Continuity test.
Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within
specifications replace as necessary.
The Chrysler Town and Country is available with optional Automatic Headlamps. For diagnosis,
refer to the proper Body Diagnostic Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Service and Repair > Headlight Switch
Headlamp Switch: Service and Repair Headlight Switch
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable.
Headlamp Switch
2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. 3. Remove
screws holding the headlamp switch bezel to cluster bezel. 4. Disconnect the wire connectors from
the headlamp switch and wire connector from the power mirror switch. 5. Remove headlamp switch
bezel from cluster bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Service and Repair > Headlight Switch > Page 650
Headlamp Switch: Service and Repair Headlight Switch Lamp
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. 3.
Disconnect wire connectors. 4. Remove headlamp switch bezel from instrument cluster bezel.
Headlamp Switch Lamp
5. Rotate bulb socket counterclockwise one quarter turn. 6. Pull bulb socket from headlamp switch.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations
Speed Control Switches
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations > Page 654
Horn Switch: Service and Repair
REMOVAL AND INSTALLATION
The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately.
Refer to Passive Restraints for Driver Airbag Module Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams
Multi-Function Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 658
Turn Signal Switch: Testing and Inspection
To test turn signal, headlamp beam select and optical horn portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Turn Signal - Multi-Function Switch Pin Numbers
2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the
above image for proper pin numbers and Turn
Signal Multi-Function Switch Test table.
TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between
Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 659
Turn Signal Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable.
3. Remove upper and lower steering column shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and
Operation
Battery Temperature Sensor: Description and Operation
OPERATION
The temperature sensor, in the PCM, is used to determine the battery temperature. This
temperature data, along with data from monitored line voltage, is used by the PCM to vary the
battery charging rate. System voltage will be higher at colder temperatures and is gradually
reduced at warmer temperatures.
The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II
monitors are either enabled or disabled depending upon the battery temperature sensor input
(example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor ...................................................................................................................
................................................... 14 Nm (125 in. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
668
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
669
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
670
Camshaft Position Sensor: Description and Operation
Camshaft Position Sensor Location
DESCRIPTION
The camshaft position sensor is mounted in the front of the timing case cover.
Camshaft Position Sensor
Camshaft Sprocket
OPERATION
The camshaft position sensor provides cylinder identification to the Powertrain Control Module
(PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass
underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the
pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each
group of camshaft pulses.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
671
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Ignition Coil Pack
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder
the flat spot and notches identify, they do not indicate TDC position.
CAMSHAFT POSITION SENSOR-PCM INPUT
The PCM determines fuel injection synchronization and cylinder identification from inputs provided
by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM
determines crankshaft position.
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it.
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft
pulses.
The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of
the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel
Injection-Service Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
672
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
673
Camshaft Position Sensor: Service and Repair
REMOVAL
Camshaft Position Sensor
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector.
Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt.
Camshaft Sensor Removal/Installation
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674
3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the
sensor lead. There is an O-ring on the sensor case. The O-ring may make removal
difficult. A light tap to top of sensor prior to removal may reduce force needed for removal.
INSTALLATION
Camshaft Position Sensor And Spacer
If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If
the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is
positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring
prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor
down until contact is made with the camshaft gear. While holding the sensor in this position, install
and tighten the retaining bolt 14
Nm (125 in. lbs.) torque.
4. Connect camshaft position sensor electrical connector to harness connector.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Temperature Sensor 7 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 678
Coolant Temperature Sensor/Switch (For Computer): Locations
Engine Coolant Temperature Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Information > Specifications > Page 679
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 680
Coolant Temperature Sensor/Switch (For Computer): Service Precautions
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT
TEMPERATURE (ECT) SENSOR.
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Information > Specifications > Page 681
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT
The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40°
F to 265° F).
The engine coolant temperature sensor provides an input voltage to the PCM. As coolant
temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM.
When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The engine coolant sensor is also used for cooling fan control.
Engine Coolant Temperature Sensor
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
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Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Engine Coolant Temperature Sensor
1. With the key off, disconnect wire harness connector from coolant temperature sensor.
Engine Coolant Temperature Sensor
2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter
should read as follows:
a. ECT STET at normal operating temperature around 200°F should read approximately 700 to
1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately
7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater
than 1 ohm, repair the wire harness as necessary.
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Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT
TEMPERATURE SENSOR.
REMOVAL
1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant
sensor electrical connector. 3. Remove coolant sensor.
INSTALLATION
1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector
to sensor. 3. Fill cooling system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Page 687
Crankshaft Position Sensor Location
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Page 688
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Page 689
Crankshaft Position Sensor: Description and Operation
DESCRIPTION
Crankshaft Position Sensor Location
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing. The bottom of the sensor is positioned next to the drive plate.
OPERATION
Crankshaft Position Sensor
Timing Slots
The crankshaft position sensor detects slots cut into the transmission driveplate extension. There
are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the
position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last
slot,
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Page 690
it determines crankshaft position (which piston will next be at TDC) from the camshaft position
sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°,
and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
CRANKSHAFT POSITION SENSOR-PCM INPUT
The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3
sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of
the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position
(which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM
one engine revolution to determine crankshaft position.
The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing
and presence of misfire. Once crankshaft position has been determined, the PCM begins
energizing the injectors in sequence.
The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor.
The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of
sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft
position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures.
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Page 691
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
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Page 692
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Raise and support vehicle.
Crankshaft Position Sensor Connector
2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3.
Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out
of the trans axle housing.
INSTALLATION
Crankshaft Position Sensor And Spacer
NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the face of the new sensor.
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
Fuel Level Sensor: Locations
The level sensor is attached to the side of the fuel pump module.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 696
Fuel Level Sensor: Description and Operation
DESCRIPTION
The level sensor is attached to the side of the fuel pump module. The level sensor consists of a
float, an arm, and a variable resistor.
OPERATION
As the fuel level increases, the float and arm move up. This decreases the sending unit resistance,
causing the fuel gauge on the instrument panel to read full.
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Fuel Level Sensor: Testing and Inspection
This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit.
Level Sensor Diagnosis
The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the fuel level changes. To test the level sensor,
connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump
module connector. Move the float lever to the positions shown in the resistance chart. Record the
resistance at each point. Replace the level sensor if the resistance is not within specifications.
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Fuel Level Sensor: Service and Repair
REMOVAL
Remove fuel pump module. Refer to Fuel Pump Module.
Fuel Pump/Level Sensor Electrical Connector
1. Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of
the fuel pump module electrical connector.
NOTE: The pump module harness on TOP of flange is not serviceable or removable.
Wire Terminal Locking Wedge
2. Pull off blue locking wedge.
Wire Terminal Locking Finger
3. Using a small screwdriver lift locking finger away from terminal and push terminal out of
connector.
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Removing Wires From Connector
4. Push level sensor signal and ground terminals out of the connector.
Loosening Level Sensor
5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing.
Push level sensor down slightly.
Level Sensor Removal/Installation
6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of
installation channel in module.
INSTALLATION
1. Insert level sensor wires into bottom of opening in module.
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Groove In Back Side Of Level Sensor
2. Wrap wires into groove in back of level sensor.
Installation Channel
3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into
place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector.
Push the wires up through the connector and then pull them down until they lock in place. Ensure
signal and
ground wires are installed in the correct position.
5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module
electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 704
Knock Sensor
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 705
Knock Sensor: Description and Operation
Knock Sensor
KNOCK SENSOR-PCM INPUT
The knock sensor is only on these engines.
The knock sensor threads into the side of the cylinder block in front of the starter. When the knock
sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response,
the PCM retards ignition timing for all cylinders by a scheduled amount.
Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM.
As the intensity of the engine knock vibration increases, the knock sensor output voltage also
increases.
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Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: ignition timing,
cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude
increases with the increase of engine knock. The knock sensor can be tested with a digital
voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to
approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set.
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Knock Sensor: Service and Repair
Knock Sensor
The knock sensor threads into the side of the cylinder block in front of the starter.
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening
effects knock sensor performance, possibly
causing improper spark control.
2. Attach electrical connector to knock sensor.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
Sensor Tightening Torque 35 in.lb
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> Page 711
MAP Sensor
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> Page 712
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> Page 713
Manifold Pressure/Vacuum Sensor: Description and Operation
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT
The PCM supplies 5 volts to the MAP sensor. The MAP sensor converts intake manifold pressure
into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP
sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage
increases proportionately.
During cranking, before the engine starts running, the PCM determines atmospheric air pressure
from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold
pressure from the MAP sensor voltage.
Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and
the air/fuel mixture.
MAP Sensor
MAP Sensor
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MAP Sensor
The MAP sensor mounts to the intake manifold near the throttle body inlet to the manifold. The
sensor connects electrically to the PCM.
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> Page 715
Manifold Pressure/Vacuum Sensor: Testing and Inspection
To perform a complete test of the MAP sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following:
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
MAP Sensor Connector
1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3.
With the ignition switch ON and the engine not
running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot,
neutral idle speed condition. If OK, go to next step. If not OK, go to step 3.
2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness
condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1
and PCM terminal 43. If OK, go to next step. If not OK, repair as required. 4. Test MAP sensor
supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should
be approximately 5 volts (±
0.5V). Five volts ± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. If
not OK, repair or replace the wire harness as required.
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> Page 716
Manifold Pressure/Vacuum Sensor: Service and Repair
Map Absolute Pressure Sensor
REMOVAL
1. Disconnect electrical connector from MAP sensor. 2. Remove two screws holding sensor to the
intake manifold.
INSTALLATION
1. Reverse the above procedure for installation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications
Oxygen Sensor: Specifications
Upstream and Downstream Oxygen Sensor 27 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Bank Locations
Oxygen Sensor: Locations Oxygen Sensor Bank Locations
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling
and Exhaust/Engine/Tune-up and Engine
Performance Checks/Firing Order/Specifications
- If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered
O2 Sensor 1/2, even if it uses two upstream
HO2S.
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Bank Locations > Page 722
Oxygen Sensor: Locations Oxygen Sensor(s)
Heated Oxygen Sensor
Downstream Heated Oxygen Sensor
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Oxygen Sensor: Diagrams
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Oxygen Sensor: Service Precautions
WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN
SERVICING THE OXYGEN SENSOR
.
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Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling
and Exhaust/Engine/Tune-up and Engine
Performance Checks/Firing Order/Specifications
- If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered
O2 Sensor 1/2, even if it uses two upstream
HO2S.
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Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (O2S SENSOR)-PCM INPUT
The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas
in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel
mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel
mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to
electrical voltage, the sensors act as a rich-lean switch.
The oxygen sensors are equipped with a heating element that keeps the sensors at proper
operating temperature during all operating modes. Maintaining correct sensor temperature at all
times allows the system to enter into closed loop operation sooner. Also, it allows the system to
remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM
monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly.
During Open Loop operation the PCM ignores the 02 sensor input. The PCM adjusts injector pulse
width based on preprogrammed (fixed) values and inputs from other sensors.
The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and
downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element.
The heating elements reduce the time required for the sensors to reach operating temperature.
UPSTREAM HEATED OXYGEN SENSOR
Heated Oxygen Sensor
Heated Oxygen Sensor
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Heated Oxygen Sensor
The upstream O2S is located in the exhaust manifold and provides an input voltage to the PCM.
The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to
fine tune the air/fuel ratio by adjusting injector pulse width.
DOWNSTREAM HEATED OXYGEN SENSOR
Downstream Heated Oxygen Sensor
The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic
convertor. The downstream heated oxygen sensor input is used to detect catalytic convertor
deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match
the upstream sensor input except for a slight time delay. By comparing the downstream heated
oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor
efficiency.
When the catalytic converter efficiency drops below emission standards, the PCM stores a
diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information,
refer to Emission Control Systems.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Oxygen Sensor: Testing and Inspection
Use an ohmmeter to test the heating element of the oxygen sensors. Disconnect the electrical
connector from each oxygen sensor. The white wires in the sensor connector are the power and
ground circuits for the heater. Connect the ohmmeter test leads to terminals of the white wires in
the heated oxygen sensor connector. Replace the heated oxygen sensor if the resistance is not
between 4 and 7 ohms.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair >
Downstream Oxygen Sensor Replacement
Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement
REMOVAL
1. Raise and support vehicle.
WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN
SERVICING THE OXYGEN SENSOR.
Oxygen Sensor Grommet Cover
2. Remove grommet cover to expose connector.
Oxygen Sensor Connector Locking Tab
3. Push locking tab back and unplug oxygen sensor electrical connector.
Oxygen Sensor Removal/Installation
4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 5. When the sensor is
removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using
original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
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Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair >
Downstream Oxygen Sensor Replacement > Page 731
INSTALLATION
1. Reverse removal procedure to install a new sensor.
New sensors are packaged with compound on the threads and no additional compound is required.
The sensor must be tightened to 27 Nm (20 ft. lbs.) torque.
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Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement
Upstream Heated Oxygen Sensor
The oxygen sensor is installed in the exhaust manifold .
CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector.
WARNING: THE EXHAUST MANIFOLD AND CATALYTIC CONVERTER MAY BE EXTREMELY
HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR.
REMOVAL
1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such
as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust
manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
New sensors are packaged with compound on the threads and no additional compound is required.
The sensor must be tightened to 27 Nm (20 ft. lbs.) torque.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications
Throttle Position Sensor: Specifications
Throttle Position Sensor Screw 2 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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736
Throttle Position Sensor
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738
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
THROTTLE POSITION SENSOR (TPS)-PCM INPUT
The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a
variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade
position. As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from
approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with
inputs from other sensors, the PCM uses the TPS input to determine current engine operating
conditions and adjust fuel injector pulse width and ignition timing.
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739
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to
the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The
center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply
and the remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS
output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output
voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase
as the throttle plate moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM connections before replacing the TPS.
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740
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws.
Servicing Throttle Position Sensor
4. Lift throttle position sensor off throttle shaft.
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
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The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
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Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 746
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
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Transmission Range Sensor
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Technical Service Bulletins > Page 748
Connector Pin Identification
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Technical Service Bulletins > Page 749
Transmission Position Switch/Sensor: Description and Operation
Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical
TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT
The park/neutral switch is located on the transaxle housing.
If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral.
This input is used to determine idle speed (varying with gear selection) and ignition timing advance.
The park neutral switch is sometimes referred to as the neutral safety switch.
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Technical Service Bulletins > Page 750
Transmission Position Switch/Sensor: Service and Repair
The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
Fig. 20
3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission
range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8.
Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
Fig. 21
11. Place valve body on workbench (Fig. 21).
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Technical Service Bulletins > Page 751
Fig. 22
12. Remove TRS retaining screw (Fig. 22).
Fig. 23
13. Remove manual shaft seal (Fig. 23).
Fig. 24
14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24).
INSTALLATION
1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.)
Reseal transaxle oil pan using RTV.
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
Fig. 26
Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the
PCM. The output speed sensor is located on the side of
the transaxle.
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Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 766
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Information and Instructions > Page 768
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Information and Instructions > Page 769
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Information and Instructions > Page 770
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Information and Instructions > Page 771
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Vehicle Speed Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Vehicle Speed Sensor: Description and Operation
Description
The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC
signals as rotation occurs. They are threaded into the transaxle case and are considered primary
inputs to the Trans- mission Control Module (TCM).
OPERATION
The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of
the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The
TCM interprets this information as input shaft rpm.
The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by
rotation of the rear planetary carrier park pawl lugs. The TCM interprets this information as output
shaft rpm.
The TCM compares the input and output speed signals to determine the following:
^ Transmission gear ratio
^ Speed ratio error detection
^ CVI calculation
The TCM also compares the input speed signal and the engine speed signal to determine the
following:
^ Torque converter clutch slippage
^ Torque converter element speed ratio
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Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications
Throttle Position Sensor: Specifications
Throttle Position Sensor Screw 2 Nm
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Throttle Position Sensor
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Throttle Position Sensor: Description and Operation
Throttle Position Sensor
THROTTLE POSITION SENSOR (TPS)-PCM INPUT
The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a
variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade
position. As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from
approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with
inputs from other sensors, the PCM uses the TPS input to determine current engine operating
conditions and adjust fuel injector pulse width and ignition timing.
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Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to
the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The
center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply
and the remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS
output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output
voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase
as the throttle plate moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM connections before replacing the TPS.
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Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws.
Servicing Throttle Position Sensor
4. Lift throttle position sensor off throttle shaft.
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor ...................................................................................................................
................................................... 14 Nm (125 in. lbs.)
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Camshaft Position Sensor: Description and Operation
Camshaft Position Sensor Location
DESCRIPTION
The camshaft position sensor is mounted in the front of the timing case cover.
Camshaft Position Sensor
Camshaft Sprocket
OPERATION
The camshaft position sensor provides cylinder identification to the Powertrain Control Module
(PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass
underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the
pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each
group of camshaft pulses.
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When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Ignition Coil Pack
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder
the flat spot and notches identify, they do not indicate TDC position.
CAMSHAFT POSITION SENSOR-PCM INPUT
The PCM determines fuel injection synchronization and cylinder identification from inputs provided
by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM
determines crankshaft position.
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it.
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft
pulses.
The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of
the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel
Injection-Service Procedures.
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Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
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Camshaft Position Sensor: Service and Repair
REMOVAL
Camshaft Position Sensor
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector.
Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt.
Camshaft Sensor Removal/Installation
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3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the
sensor lead. There is an O-ring on the sensor case. The O-ring may make removal
difficult. A light tap to top of sensor prior to removal may reduce force needed for removal.
INSTALLATION
Camshaft Position Sensor And Spacer
If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If
the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is
positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring
prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor
down until contact is made with the camshaft gear. While holding the sensor in this position, install
and tighten the retaining bolt 14
Nm (125 in. lbs.) torque.
4. Connect camshaft position sensor electrical connector to harness connector.
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
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Crankshaft Position Sensor Location
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Crankshaft Position Sensor: Description and Operation
DESCRIPTION
Crankshaft Position Sensor Location
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing. The bottom of the sensor is positioned next to the drive plate.
OPERATION
Crankshaft Position Sensor
Timing Slots
The crankshaft position sensor detects slots cut into the transmission driveplate extension. There
are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the
position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last
slot,
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it determines crankshaft position (which piston will next be at TDC) from the camshaft position
sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°,
and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
CRANKSHAFT POSITION SENSOR-PCM INPUT
The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3
sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of
the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position
(which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM
one engine revolution to determine crankshaft position.
The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing
and presence of misfire. Once crankshaft position has been determined, the PCM begins
energizing the injectors in sequence.
The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor.
The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of
sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft
position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures.
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Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
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Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Raise and support vehicle.
Crankshaft Position Sensor Connector
2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3.
Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out
of the trans axle housing.
INSTALLATION
Crankshaft Position Sensor And Spacer
NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the face of the new sensor.
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
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Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or
Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or
Cannot Be Removed > Page 814
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not
Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not
Turn And/Or Cannot Be Removed > Page 820
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 821
Ignition Switch Lock Cylinder: Description and Operation
DESCRIPTION
The lock cylinder is inserted in the end of the housing opposite the ignition switch.
OPERATION
Ignition Lock Cylinder Detents
The ignition key rotates the cylinder to 5 different detents: Accessory
- Off (lock)
- Unlock
- On/Run
- Start
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 822
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 823
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 827
Knock Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 828
Knock Sensor: Description and Operation
Knock Sensor
KNOCK SENSOR-PCM INPUT
The knock sensor is only on these engines.
The knock sensor threads into the side of the cylinder block in front of the starter. When the knock
sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response,
the PCM retards ignition timing for all cylinders by a scheduled amount.
Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM.
As the intensity of the engine knock vibration increases, the knock sensor output voltage also
increases.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 829
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: ignition timing,
cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude
increases with the increase of engine knock. The knock sensor can be tested with a digital
voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to
approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 830
Knock Sensor: Service and Repair
Knock Sensor
The knock sensor threads into the side of the cylinder block in front of the starter.
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening
effects knock sensor performance, possibly
causing improper spark control.
2. Attach electrical connector to knock sensor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED
NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS,
PARTS, AND 2001 MODEL YEAR PROCEDURES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS.
SUBJECT: Airbag On-Off Switches
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Convertible
1994 - **2001** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
**2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - **2001** (PL) Neon
1997 (PR) Prowler
**2001 (PT) PT Cruiser**
**2001** (RS) Town & Country/Caravan/Voyager
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 836
1996 - 1997 (SR) Viper
**2001 - 2002 (ST) Sebring Coupe/Stratus Coupe**
1997 - 2001** (TJ) Wrangler
1999 - **2001** (WJ) Grand Cherokee
1997 - **2001** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
NOTE:
**SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE
OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS
DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.**
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated) and
a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule,
consumers will be authorized for on-off switches by claiming they meet any of several criteria.
Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA
authorization letter. For more information concerning the authorization process and/or the
authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you
(dealer) to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
NOTE:
FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001
CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS
REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG
SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE
CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE
AIRBAG KIT.
**FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS,
AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N
05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE
NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.**
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 837
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 838
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 839
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 840
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 841
PARTS REQUIRED:
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have~
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on
your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 842
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch
Availibility
NO: 08-17-98 Rev. C
GROUP: Electrical
DATE: Dec. 30, 1998
SUBJECT: Airbag On-Off Switches
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED
SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL
MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
**1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan**
1995 - **1999** (AB) Ram Van/Wagon
**1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon**
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/Convertible
1994 -**1999** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan/Voyager
**1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue**
1994 - **1999** (BR) Ram Pickup
**1995 - 1996 (B7) Stealth**
1998 - **1999** (DN) Durango
**1995 - 1999 (FJ) Avenger/Sebring/Talon**
1995 - **1999** (JA) Breeze/Cirrus/Stratus
1996 - **1999** (JX) Sebring Convertible
1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - **1999** (NS) Town & Country/Caravan/ Voyager
1995 - **1999** (PL) Neon
1996 - 1997 (SR) Viper
1997 - **1999** (TJ) Wrangler
1997 - **1999** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. Other applicable passenger vehicles will be announced as soon as the switches are
available. The switches are packaged in a kit containing all necessary parts (except as indicated)
and a detailed instruction sheet.
Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for
on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be
installed without the vehicle owner presenting the NHTSA authorization letter. For more information
concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety
Hotline at 1-800-424-9393.
We encourage you (dealer) to install these switches when the customer is interested in doing so
and has the necessary NHTSA authorization.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 843
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 844
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 845
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 846
PARTS REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 847
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have.
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for
your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 848
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations
Impact Sensor: Locations
Instrument Panel Supports
The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 852
Impact Sensor: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch
> Component Information > Diagrams
Seat Belt Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature
Sensor > Component Information > Description and Operation
Battery Temperature Sensor: Description and Operation
OPERATION
The temperature sensor, in the PCM, is used to determine the battery temperature. This
temperature data, along with data from monitored line voltage, is used by the PCM to vary the
battery charging rate. System voltage will be higher at colder temperatures and is gradually
reduced at warmer temperatures.
The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II
monitors are either enabled or disabled depending upon the battery temperature sensor input
(example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch
Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch
Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 869
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 875
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 876
Ignition Switch Lock Cylinder: Description and Operation
DESCRIPTION
The lock cylinder is inserted in the end of the housing opposite the ignition switch.
OPERATION
Ignition Lock Cylinder Detents
The ignition key rotates the cylinder to 5 different detents: Accessory
- Off (lock)
- Unlock
- On/Run
- Start
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 877
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 878
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations
Transmission Range Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations > Page 882
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Locations
Autostick/Overdrive Off
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 888
Autostick/Overdrive Switch Connector Pin Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations
Transmission Mode Switch: Locations
For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 892
Transmission Mode Switch: Diagrams
For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Transmission Range Sensor - Production Change > Page 897
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Transmission Range Sensor - Production Change > Page 898
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page
899
Transmission Range Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page
900
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page
901
Transmission Position Switch/Sensor: Description and Operation
Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical
TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT
The park/neutral switch is located on the transaxle housing.
If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral.
This input is used to determine idle speed (varying with gear selection) and ignition timing advance.
The park neutral switch is sometimes referred to as the neutral safety switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page
902
Transmission Position Switch/Sensor: Service and Repair
The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
Fig. 20
3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission
range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8.
Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
Fig. 21
11. Place valve body on workbench (Fig. 21).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page
903
Fig. 22
12. Remove TRS retaining screw (Fig. 22).
Fig. 23
13. Remove manual shaft seal (Fig. 23).
Fig. 24
14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24).
INSTALLATION
1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.)
Reseal transaxle oil pan using RTV.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control >
Page 912
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise
Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise
Control > Page 918
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 919
Transmission Speed Sensor: Specifications
Speed Sensor Input 20 ft.lb
Output 20 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 920
Input Speed Sensor/Output Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 923
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor
Transmission Speed Sensor: Service and Repair Input Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 25
The input speed sensor is located to the left of the manual shift lever (Fig. 25).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor > Page
926
Transmission Speed Sensor: Service and Repair Output Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 26
The output speed sensor is located to the right of the manual shift lever (Fig. 26).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Description and Operation
Heated Glass Element Switch: Description and Operation
SYSTEM OPERATION
HVAC Control Panel/Rear Window Defogger Switch
The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when
the switch is activated. The switch energizes the timing circuit and activates the rear window
defogger relay. The relay controls the current to flow to the grids of the rear window defogger,
heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be
on for approximately 10 minutes or until the control switch or ignition is turned off.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Testing and Inspection
Power Window Switch: Testing and Inspection
1. Remove the desired switch to be tested from the door trim panel. Driver's side (master) or
passenger side. Refer to Power Window Switch and
Bezel Assembly Replacement.
Power Window Master Switch Connector
2. Using an ohmmeter, Test driver door switch for continuity as described.
*
MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS
11 AND 6
Passenger Door Power Window Switch
3. Test passenger door switch for continuity as described. 4. If the results are not OK, replace the
switch. The power window master switch has a Auto-Down feature. The switch is equipped with
two detent
positions when actuating the power window OPEN. The first detent position allows the window to
roll down and stop when the switch is released. The second detent position actuates an integral
express roll down relay that rolls the window down after the switch is released. When the express
down relay senses an amperage spike (motor pushing against down stop) in the feed circuit,
current is turned off to the motor. The AUTO feature can be cancelled by actuating the switch UP
or DOWN while window is in motion. Failure of the electronic switch to detect an amperage spike
will cause the switch to disconnect after approximately 11 seconds.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Testing and Inspection > Page 934
Power Window Switch: Service and Repair
Window Switch and Bezel Replacement The Power Window Switch is integral to the bezel. If
service to the switch is required, the complete bezel must be replaced. The Owe Door Lock Switch
is serviced separately and must be transferred to the new bezel.
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Open door, remove screw cover near
inside door release handle. 3. Remove two screws to Power Window Switch and Bezel Assembly
One under the screw cover removed in previous step and one to the rear of the
front door vent opening.
4. Pull out and up on bezel to release from door trim panel. 5. Disconnect two switch connectors. 6.
Remove two door lock switch retaining screws and remove switch from bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Diagrams
Washer Fluid Level Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection
Windshield Washer Switch: Testing and Inspection
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Fig.1 Wiper/Washer Switch Pin Call Out
Windshield Wiper and Washer / Multi-function Switch Test
2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper
and Washer / Multi-function Switch Test table.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 942
Windshield Washer Switch: Service and Repair
REMOVAL AND INSTALLATION
Refer to Turn Signal and Flashers, for Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Diagrams
Multi-Function Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Testing and Inspection > Failed Park Switch
Wiper Switch: Testing and Inspection Failed Park Switch
If the wiper park switch has failed the windshield wipers will operate as follows: SWITCH OFF Wipers stop in current location regardless of the park signal. INTERMITTENT MODE - Wipers
operate at low speed for one or more extra wipes or continuously. LOW SPEED - Wipers operate
at low speed. HIGH SPEED - Wipers operate at high speed. PULSE WIPE - Wipers will not
operate. WIPE AFTER WASH - Wipers operate at low speed in any mode setting. Wipers operate
only while wash button is depressed with switch in OFF mode, wipers stop in mid-cycle when
button is released.
Wiper System Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Testing and Inspection > Failed Park Switch > Page 948
Wiper System Diagnosis (Part 2 Of 2)
The windshield wiper park switch and circuit is monitored by the BCM. The park switch and circuit
can be tested using the Wiper System Diagnosis table.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Testing and Inspection > Failed Park Switch > Page 949
Wiper Switch: Testing and Inspection Wiper Switch Test
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Fig.1 Wiper/Washer Switch Pin Call Out
Windshield Wiper and Washer / Multi-function Switch Test
2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper
and Washer / Multi-function Switch Test table.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Testing and Inspection > Page 950
Wiper Switch: Service and Repair
REMOVAL AND INSTALLATION
Refer to Turn Signal and Flashers, for Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative
Fuels or Electric Engine
Alignment: Specifications Vehicles Using Alternative Fuels or Electric Engine
NOTES:
- All specifications are given in degrees.
- All wheel alignments are to be set at curb height.
FRONT:
Camber (All Vehicles Except Those With Tire Sizes P205/75R15, P215/65/R16 or P215/60/R17):
Preferred Setting .................................................................................................................................
..................................................................... +0.15° Acceptable Range ..............................................
........................................................................................................................................ -0.25 to
+0.55°
Camber (Vehicles With Tire Sizes P205/75R15, P215/65/R16 or P215/60/R17): Preferred Setting ..
..............................................................................................................................................................
...................................... +0.05° Acceptable Range .............................................................................
......................................................................................................... -0.25 to +0.55°
Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ...............................................
.........................................................................................................................................................
+0.0° Acceptable Range ......................................................................................................................
................................................................................ 0.50°
Caster [1]: Preferred Setting ................................................................................................................
...................................................................................... +1.40° Acceptable Range .............................
.......................................................................................................................................................
+0.40° to +2.40°
Cross Caster (Maximum Side-to-Side Difference): Preferred Setting .................................................
.........................................................................................................................................................
0.0° Acceptable Range ........................................................................................................................
.............................................................................. 1.00°
Total Toe [2]: Preferred Setting ...........................................................................................................
........................................................................................... +0.10° Acceptable Range ........................
.............................................................................................................................................................
-0.10° to +0.30°
Total Toe (Maximum Side-to-Side Difference): Preferred Setting .......................................................
................................................................................................................................................... 0.0°
Acceptable Range ...............................................................................................................................
....................................................................... 0.06°
Curb Height: Standard
.........................................................................................................................................................
783.5 mm ±10 mm (30.85 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
REAR:
Camber [1]: Preferred Setting ..............................................................................................................
......................................................................................... -0.10° Acceptable Range ..........................
............................................................................................................................................................
-0.35 to +0.15°
Total Toe [1, 2]: Preferred Setting .......................................................................................................
................................................................................................... 0.0° Acceptable Range ....................
..............................................................................................................................................................
... -0.40° to +0.40°
Thrust Angle [1]: Preferred Setting ......................................................................................................
.................................................................................................... 0.0° Acceptable Range ...................
..............................................................................................................................................................
.... -0.30° to +0.30°
Curb Height: Standard
.........................................................................................................................................................
802.5 mm ±10 mm (31.59 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
[1] For reference only. These are non-adjustable angles.
[2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split
between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is
toe-in and negative toe is toe-out.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative
Fuels or Electric Engine > Page 956
Alignment: Specifications All Except W/Tire Sizes P205/75/R14, P215/65R/16 or P215/60/R17
NOTES:
- All specifications are given in degrees.
- All wheel alignments are to be set at curb height.
FRONT:
Camber: Preferred Setting ...................................................................................................................
................................................................................... +0.15° Acceptable Range ................................
......................................................................................................................................................
-0.25 to +0.55°
Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ...............................................
.........................................................................................................................................................
+0.0° Acceptable Range ......................................................................................................................
................................................................................ 0.50°
Caster [1]: Preferred Setting ................................................................................................................
...................................................................................... +1.40° Acceptable Range .............................
.......................................................................................................................................................
+0.40° to +2.40°
Cross Caster (Maximum Side-to-Side Difference): Preferred Setting .................................................
.........................................................................................................................................................
0.0° Acceptable Range ........................................................................................................................
.............................................................................. 1.00°
Total Toe [2]: Preferred Setting ...........................................................................................................
........................................................................................... +0.10° Acceptable Range ........................
.............................................................................................................................................................
-0.10° to +0.30°
Total Toe (Maximum Side-to-Side Difference): Preferred Setting .......................................................
................................................................................................................................................... 0.0°
Acceptable Range ...............................................................................................................................
....................................................................... 0.06°
Curb Height: Standard
.........................................................................................................................................................
747.5 mm ±10 mm (29.43 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
REAR:
Camber [1]: Preferred Setting ..............................................................................................................
............................................................................................ 0.0° Acceptable Range ...........................
...........................................................................................................................................................
-0.25 to +0.25°
Total Toe [1, 2]: Preferred Setting .......................................................................................................
................................................................................................... 0.0° Acceptable Range ....................
..............................................................................................................................................................
... -0.40° to +0.40°
Thrust Angle [1]: Preferred Setting ......................................................................................................
.................................................................................................... 0.0° Acceptable Range ...................
..............................................................................................................................................................
.... -0.30° to +0.30°
Curb Height: Standard
.........................................................................................................................................................
766.0 mm ±10 mm (30.15 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
[1] For reference only. These are non-adjustable angles.
[2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split
between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is
toe-in and negative toe is toe-out.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative
Fuels or Electric Engine > Page 957
Alignment: Specifications With Tire Sizes P205/75/R14, P215/65R/16 or P215/60/R17
NOTES:
- All specifications are given in degrees.
- All wheel alignments are to be set at curb height.
FRONT:
Camber: Preferred Setting ...................................................................................................................
................................................................................... +0.05° Acceptable Range ................................
......................................................................................................................................................
-0.35 to +0.45°
Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ...............................................
.........................................................................................................................................................
+0.0° Acceptable Range ......................................................................................................................
................................................................................ 0.50°
Caster [1]: Preferred Setting ................................................................................................................
...................................................................................... +1.40° Acceptable Range .............................
.......................................................................................................................................................
+0.40° to +2.40°
Cross Caster (Maximum Side-to-Side Difference): Preferred Setting .................................................
.........................................................................................................................................................
0.0° Acceptable Range ........................................................................................................................
.............................................................................. 1.00°
Total Toe [2]: Preferred Setting ...........................................................................................................
........................................................................................... +0.10° Acceptable Range ........................
.............................................................................................................................................................
-0.10° to +0.30°
Total Toe (Maximum Side-to-Side Difference): Preferred Setting .......................................................
................................................................................................................................................... 0.0°
Acceptable Range ...............................................................................................................................
....................................................................... 0.06°
Curb Height: Standard
.........................................................................................................................................................
753.5 mm ±10 mm (29.66 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
REAR:
Camber [1]: Preferred Setting ..............................................................................................................
............................................................................................ 0.0° Acceptable Range ...........................
...........................................................................................................................................................
-0.25 to +0.25°
Total Toe [1, 2]: Preferred Setting .......................................................................................................
................................................................................................... 0.0° Acceptable Range ....................
..............................................................................................................................................................
... -0.40° to +0.40°
Thrust Angle [1]: Preferred Setting ......................................................................................................
.................................................................................................... 0.0° Acceptable Range ...................
..............................................................................................................................................................
.... -0.30° to +0.30°
Curb Height: Standard
.........................................................................................................................................................
772.0 mm ±10 mm (30.39 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
[1] For reference only. These are non-adjustable angles.
[2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split
between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is
toe-in and negative toe is toe-out.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 958
Alignment: Description and Operation
Vehicle wheel alignment is the proper adjustment of all interrelated front and rear suspension
angles. These angles are what effects the handling and steering of the vehicle when it is in motion.
The method of checking a vehicle's front and rear wheel alignment will vary depending on the type
and manufacturer of the equipment being used. Instructions furnished by the manufacturer of the
equipment being used should always be followed to ensure accuracy of the alignment, except
when alignment specifications recommended by Chrysler Corporation differ. Typical wheel
alignment angles and measurements are camber, caster, toe, and thrust angle.
Alignment Camber And Toe
- Camber is the number of degrees the top of the tire and wheel are tilted either inward or outward.
Camber is a tire wearing angle. Excessive negative camber will cause tread wear at the inside of
the tire, while excessive positive camber will cause outside tire wear.
- Caster is the number of degrees of forward or rearward tilt of the steering knuckle. Forward tilt
provides a negative caster angle, while rearward tilt provides a positive caster angle. Caster is not
adjustable on this vehicle.
- Cross camber is the difference between left and right camber. The right side camber is to be
subtracted from the left, resulting in the cross camber reading. For example, if the left camber is
+0.3° and the right camber is 0.0°, the cross camber would be +0.3°.
- Toe is measured in degrees or inches and is the difference in width between the centered leading
and trailing edges of the tires on the same axle. Toe-in means that the front width is more narrow
than the rear. Toe-out means that the front width is wider than the rear.
- Thrust angle is defined as the average of the toe settings on each rear wheel. If this measurement
is out of specification, readjust the rear wheel toe so that each wheel has 1/2 of the total toe
measurement. When readjusting, do not exceed the total toe specification.
Wheel alignment on this vehicle is to be checked and all alignment adjustments made with the
vehicle at its curb height specification. Curb height is the riding height of the vehicle measured from
a certain point on the vehicle to the ground while the vehicle is setting on a flat, level surface.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 959
Alignment: Testing and Inspection
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct the wheel alignment, the following inspection and
necessary corrections must be made to the vehicle to ensure proper alignment. 1. Be sure the fuel
tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the
vehicle and the alignment
specifications.
2. The passenger and luggage compartments of the vehicle should be free of any load that is not
factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the
recommended air pressure. All tires must be the same size and in good condition
with approximately the same tread wear.
4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension
component fasteners for looseness and torque. 6. Inspect the lower front ball joints and all steering
linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the
suspension components for signs of wear or deterioration. If any bushings show signs of wear or
deterioration, they should be replaced prior to aligning the vehicle.
8. Check vehicle curb height to verify it is within specifications. If curb height is out of specifications,
check for broken or sagged springs.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Curb Height
Measurement
Alignment: Service and Repair Curb Height Measurement
The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its
required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level
surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended
pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with
the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not
adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak
suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and
the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil
spring height to a correct new or known good coil spring. The heights should vary if the suspect
spring is weak. 1. Measure from the inboard edge of the wheel opening fender lip directly above
the wheel center (spindle), to the floor or alignment rack surface. 2. When measuring, the
maximum left-to-right differential is not to exceed 12.5 mm (0.5 inch). 3. Compare the
measurements to the specifications.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Curb Height
Measurement > Page 962
Alignment: Service and Repair Wheel Alignment
1. Position the vehicle on an alignment rack. 2. Perform the PRE-WHEEL ALIGNMENT
INSPECTION. 3. Install all required alignment equipment on the vehicle per the alignment
equipment manufacturer's instructions. On this vehicle, a four-wheel
alignment is recommended.
NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be
jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing
each end of vehicle an equal number of times. The bumper should always be released when
vehicle is at the bottom of the jounce cycle.
4. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current
alignment settings to the vehicle specifications for
camber, caster and toe-in.
5. If front camber and caster are not within specifications, proceed to CAMBER AND CASTER
below. If caster and camber are within
specifications, proceed to TOE which can be found following CAMBER AND CASTER. Rear
camber, caster and toe are not adjustable. If found not to be within specifications, reinspect for
damaged suspension or body components and replace as necessary.
CAMBER AND CASTER
Camber and caster settings on this vehicle are determined at the time the vehicle is designed, by
the location of the vehicle's suspension components. This is referred to as NET BUILD. The result
is no required adjustment of camber and caster after the vehicle is built or when servicing the
suspension components. Thus, when performing a wheel alignment, caster and camber are not
normally considered adjustable angles. Camber and caster should be checked to ensure they meet
vehicle specifications. If front camber is found not to meet alignment specifications, it can be
adjusted using an available camber adjustment bolt package. Before installing a camber
adjustment bolt package on a vehicle found to be outside the specifications, inspect the suspension
components for any signs of damage or bending.
CAUTION: Do not attempt to adjust the vehicles wheel; alignment by heating, bending or by
performing any other modification to the vehicle's front suspension components or body.
If camber readings are not within specifications, use the following procedure to install the front
camber adjustment bolt package and then adjust front camber.
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
The camber adjustment bolt package contains 2 flange bolts, 2 cam bolts, 2 dog bone washers,
and 4 nuts. This package services both sides of the vehicle. Use the package to attach the strut
clevis bracket to the steering knuckle after the strut clevis bracket has been modified. To install and
adjust the camber adjustment bolt package, follow the procedure below. 1. Raise the vehicle until
its tires are not supporting the weight of the vehicle. 2. Remove the front tire and wheel assemblies.
CAUTION: When removing the steering knuckle from the strut clevis bracket, do not put a strain on
the brake flex hose. Also, do not let the weight of the steering knuckle assembly be supported by
the brake flex hose when removed from the strut assembly. If necessary use a wire hanger to
support the steering knuckle assembly or if required remove the brake flex hose from the caliper
assembly.
CAUTION: The knuckle to strut assembly attaching bolt shanks are serrated and must not be
turned during removal. Remove the nuts while holding the bolts stationary.
Clevis Bracket To Steering Knuckle Attaching Bolts
3. Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts and discard.
Separate the steering knuckle from the strut clevis
bracket and position steering knuckle so it is out of the way of the strut.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Curb Height
Measurement > Page 963
Strut Clevis Bracket Bolt Hole Grinding Area
CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the
hole beyond the indentations on the sides of the strut clevis bracket.
4. Using an appropriate grinder and grinding wheel, slot the bottom hole in both sides of the strut
clevis bracket.
CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assembly. Only the flange bolts, cam bolts, and dog
bone washers from the service package must be used to attach the steering knuckle to the strut
after the mounting hole is slotted.
Package Bolts Correctly Installed (left Shown)
5. Position the knuckle back into the strut clevis bracket. Install a flanged bolt from the service
package into the upper mounting hole. Install a cam
bolt into the bottom mounting hole. Both bolts should point forward once installed.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Curb Height
Measurement > Page 964
Dog Bone Washer And Nuts Installed On Attaching Bolts
6. Install a dog bone washer on the steering knuckle to strut clevis bracket attaching bolts, then
install the nuts onto the bolts from the service
package. Tighten the bolts just enough to hold the steering knuckle in position when adjusting
camber, while still allowing the steering knuckle to move in clevis bracket.
7. Repeat the procedure to the other side strut clevis bracket. 8. Reinstall both front tire and wheel
assemblies and tighten to specifications. 9. Lower the vehicle. Jounce the front and rear of vehicle
an equal amount of times.
Camber Adjustment Cam Bolt
10. Adjust the front camber to the preferred setting by rotating the lower eccentric cam bolt against
the cam stop areas on the strut clevis bracket.
When camber is set, tighten the upper strut clevis bracket bolt and lower cam bolt. Again jounce
front and rear of vehicle an equal amount of times and verify front camber setting. Torque both
front strut to steering knuckle attaching bolts to 90 Nm (65 ft. lbs.) plus an additional 1/4 turn after
the required torque is met.
11. If toe readings obtained are not within the required specification range, adjust toe to meet the
preferred specification setting. Toe is adjustable
using the following procedure.
TOE
1. Center the steering wheel and lock in place using a steering wheel clamp.
CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe
adjustment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Curb Height
Measurement > Page 965
Front Wheel Toe Adjustment
2. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate
inner tie rods of steering gear to set front toe to the
preferred toe specification.
3. Tighten tie rod jam nuts to 75 Nm (55 ft. lbs.) torque. 4. Adjust steering gear to tie rod boots at
the inner tie rod. 5. Remove steering wheel clamp. 6. Remove the alignment equipment. 7. Road
test the vehicle to verify the steering wheel is straight and the vehicle does not wander or pull.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Pressure, Vacuum and Temperature Specifications
Fuel Pressure: Pressure, Vacuum and Temperature Specifications
Fuel Pressure
Key On, Engine Off ..............................................................................................................................
......................................... (approx.) 338 kPa (49 psi)
Note: Using the DRB Scan Tool, access ASD Fuel System Test. The ASD Fuel System Test will
activate the fuel pump and pressurize the system.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain
energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off
position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 971
Fuel Pressure: Capacity Specifications
Information not supplied by the manufacturer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications
Idle Speed: Specifications
Minimum Air Flow Idle Odometer <= 1000 Miles .................................................................................
.................................................................................................. 525-875 rpm Odometer >= 1000
Miles ....................................................................................................................................................
............................... 575-875 rpm
Note: Idle speed range achieved through Minimum Air Flow Idle Test
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications > Page 975
Idle Speed: Testing and Inspection
1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2.
Ensure that all accessories are off. 3. Shut off engine.
PCV Valve
4. Disconnect the PCV valve hose from the intake manifold nipple. 5. Cap the PCV valve nipple. 6.
Air Metering Fitting 6457
a. Install Air Metering Fitting 6457 (0.125 in. orifice) to the intake manifold PCV nipple. b.
Disconnect the idle purge line from the throttle body nipple.
7.
a. Cap the 3116 inch nipple. b. Connect the DRB scan tool to the data link connector.
8. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one
180°F cycle. 9. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen.
10. The following will then occur:
- Idle air control motor will fully close.
- Idle spark advance will become fixed.
- DRB scan tool displays engine rpm.
11. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum
air-flow is set correctly.
IDLE SPECIFICATION Odometer Reading = Idle RPM Below 1000 Miles = 525-875 RPM Above
1000 Miles = 575-875 RPM
12. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows:
a. Remove the throttle body from engine.
WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR
BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES
OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING
CLEANER.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications > Page 976
b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle body.
c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and
manifold side of the throttle blade. The edges of the
throttle blade and portions of the throttle bore that are closest to the throttle blade when closed,
must be free of deposits.
d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f.
Install throttle body on manifold.
g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is
not caused by the throttle body.
13. Shut off engine. 14. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple.
Reinstall the PCV valve hose. 15. Uncap the throttle body idle purge nipple and connect the idle
purge line. 16. Remove DRB scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
REMOVAL
Air Inlet Resonator
1. Remove 2 screws and air inlet resonator. 2. Loosen 3 clamps holding air cleaner housing halves
together.
Air Cleaner Housing (Left Side)
3. Remove left side of air cleaner housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 981
Air Cleaner Element
4. Remove element from air cleaner housing.
INSTALLATION
1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4.
Install hoses and air inlet resonator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service Precautions > Page 986
Fuel Pressure Release: Service and Repair
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap.
Fuel Pressure Test Port
Releasing Fuel Pressure
3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel
pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other
end of hose C-4799-1 to
fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container.
Fuel gauge C-4799-B contains hose C-4799-1.
5. Replace Pressure test port cap when finished doing pressure test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Firing Order
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications
Ignition Cable: Specifications
Cable = Maximum Resistance
#1 = 18.5 K Ohms
#2 = 15.5 K Ohms
#3 = 20.4 K Ohms
#4 = 21.2 K Ohms
#5 = 27.7 K Ohms
#6 = 26.7 K Ohms
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications > Page 997
Ignition Cable: Description and Operation
DESCRIPTION
The spark plug cables and spark plug boots are made from high temperature silicon materials. The
spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The
heat shields slide over the spark plug boots. The notches on the heat shields ensure the spark plug
boot and shield twist together during spark plug boot removal. They also identify proper heat shield
installation on the boot for service. Refer to Spark Plug Cable Replacement. All spark plug cable
leads are properly identified with cylinder numbers. The inside of the spark plug boot is coated with
a special high temperature silicone grease for greater sealing and to minimize boot bonding to the
spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature
plastic material. Under normal driving conditions, the spark plug cables have a recommended
service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles
for severe driving conditions per schedule B.
The spark plug heat shield can be reused if an ignition cable is replaced due to failure. Never reuse
heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing.
Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. The
bottom of the spark plug heat shield must make contact with the spark plug hex.
The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not
touch the coil mounting bolt to avoid abrasion/dielectric failures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications > Page 998
Ignition Cable: Service and Repair
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the ignition cables.
Spark Plug Boot/Heat Shield Orientation
The spark plug boot heat shield needs to be installed correctly on the boot before being installed on
the engine. If it is not installed correctly engine misfire would occur.
Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly.
Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely
important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield
must make contact with the spark plug socket hex.
CAUTION: Never coat the inside of spark plug boots with silicone grease. Some types of silicone
grease can damage the ignition cable conductor.
Spark Plug Cables # 3 And # 5
REMOVAL
1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the
spark plug. Twist the boot slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle.
This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug
insulator clean with a dry cloth before installation.
3. Remove the cable from the retaining bracket. Make sure that they are also detached from the
rear retaining clip mounted on the rear of the intake
manifold.
INSTALLATION
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated. A click sound should be heard
or terminal engagement is felt when the terminals are properly attached.
2. Install the cable into the retaining bracket. Make sure that they are also attached to the rear
retaining clip mounted on the rear of the intake
manifold.
3. Install the resonator.
Spark Plug Cable # 1
REMOVAL
1. Remove the accessory drive belt. 2. Remove the four bolts from the upper half of the generator
bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as
possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle.
This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug
insulator clean with a dry cloth before installation.
5. Remove the cable from the retaining bracket.
INSTALLATION
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated. A click sound should be heard
or terminal engagement is felt when the terminals are properly attached.
2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install
the accessory drive belt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications
Spark Plug: Specifications
Electrode Gap ......................................................................................................................................
.................................. 1.21-1.34 mm (0.048-0.053 in) Torque .............................................................
.............................................................................................................................................. 28 Nm
(20 ft lb)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1002
Spark Plug: Application and ID
Spark Plug ...........................................................................................................................................
............................................................... RN14PMP5 Thread .............................................................
................................................................................................................................................ (14mm)
3/4 in.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1003
Spark Plug: Description and Operation
SPARK PLUGS RESISTER
DESCRIPTION All engines use resistor spark plugs. They have resistance values ranging from
6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester.
Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Setting Spark Plug Electrode Gap
Refer to the Specifications for gap and type of spark plug.
SPARK PLUGS PLATINUM
DESCRIPTION The engine utilize platinum spark plugs. Refer to the maintenance schedule.
All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000
ohms when checked with at least a 1000 volt spark plug tester.
Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Platinum Pads
The spark plugs are double platinum and have a recommended service life of 100,000 miles for
normal driving conditions per schedule A. The spark plugs have a recommended service life of
75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both
electrode ends as shown. Extreme care must be used to prevent spark plug cross threading,
mis-gaping and ceramic insulator damage during plug removal and installation.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1004
Spark Plug: Testing and Inspection
Spark Plug Condition
Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken
porcelain insulators. Keep plugs arranged in the order in which they were removed from the
engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended.
Normal Operating Conditions
Normal Operation And Cold (Carbon) Fouling
The few deposits present will be probably light tan or slightly gray in color with most grades of
commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average
more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation for non
platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, and
then reinstalled.
CAUTION: Never attempt to tile the electrodes or use a wire brush for cleaning platinum spark
plugs. This would damage the platinum pads which would shorten spark plug life.
Some fuel refiners in several areas of the United States have introduced a manganese additive
(MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark
plug with a rust colored deposit. The rust color deposits can be mis diagnosed as being caused by
coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits.
Cold Fouling (Carbon Fouling) Cold fouling is sometimes referred to as carbon fouling because the
deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a
set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set
may be caused by a clogged air cleaner.
Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough
operating temperature during short operating periods. Replace carbon fouled plugs with new spark
plugs.
Fuel Fouling A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition
is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air
and reinstall them in the engine.
Oil Fouling A spark plug that is coated with excessive wet oil is oil fouled. In older engines, wet
fouling can be caused by worn rings or excessive cylinder wear. Break-in fouling of new engines
may occur before normal oil control is achieved. Replace oil fouled spark plugs with new ones.
Oil Or Ash Encrusted
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1005
Oil Or Ash Encrusted
If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the
combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of
spark plugs. Ash encrusted spark plugs can be cleaned and reused.
High Speed Miss When replacing spark plugs because of a high speed miss condition; wide open
throttle operation should be avoided for approximately 80 km (50 miles) after installation of new
plugs. This will allow deposit shifting in the combustion chamber to take place gradually and avoid
plug destroying splash fouling shortly after the plug change.
Electrode Gap Bridging
Electrode Gap Bridging
Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits
accumulate on the spark plugs during continuous stop-and-go driving. When the engine is
suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between
the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be
cleaned and reused.
Scavenger Deposits
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1006
Scavenger Deposits
Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a
normal condition caused by chemical additives in certain fuels. These additives are designed to
change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that
accumulation on the ground electrode and shell area may be heavy but the deposits are easily
removed. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and
reused.
Chipped Electrode Insulator
Chipped Electrode Insulator
A chipped electrode insulator usually results from bending the center electrode while adjusting the
spark plug electrode gap. Under certain conditions, severe detonation also can separate the
insulator from the center electrode. Spark plugs with chipped electrode insulators must be
replaced.
Preignition Damage
Preignition Damage
Excessive combustion chamber temperature can cause preignition damage. First, the center
electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively
deposit free. Determine if the spark plugs are the correct type, as specified on the VECI label, or if
other operating conditions are causing engine overheating.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1007
Spark Plug Overheating
Spark Plug Overheating
Overheating is indicated by a white or gray center electrode insulator that also appears blistered.
The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of
operation. This suggests that a plug with a cooler heat range rating should be used. Over
advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug
overheating.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1008
Spark Plug: Service and Repair
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
server injury/burns and can cause damage to the ignition cables.
Spark Plug Boot/Heat Shield Orientation
Use extreme care when removing and installing the spark plug cables. The spark plug boot heat
shield needs to be installed correctly on the boot before being installed on the engine. If it is not
installed correctly engine misfire would occur.
Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly
Spark Plug # 3 AND # 5
REMOVAL
1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen
bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as
close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with
the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug
boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation.
Wipe spark plug insulator]ator clean with a dry cloth before installation.
6. Remove spark plug
INSTALLATION
1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables,
make sure spark plug insulator and terminals are fully seated. A click sound should be heard or felt
when
the terminals are properly attached.
3. Install the cable into the retaining bracket. Make sure that they are also attached to the rear
retaining clip mounted on the rear of the intake
manifold.
4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6.
Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator.
Spark Plug # 1
REMOVAL
1. Remove the accessory drive belt. 2. Remove the 4 bolts from the upper half of the generator
bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as
possible to the spark plug. Twist the boot/shield assembly slightly to break its seal with
the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug
boot at an angle. This could damage the spark plug insulator, terminal, or the insulation. Wipe
spark plug insulator clean with a dry cloth before installation.
5. Remove spark plug
INSTALLATION
1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables,
make sure the coil or spark plug insulator and terminals are fully seated. A click sound should be
heard or
felt when the terminals are properly attached.
3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the
accessory drive belt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
Cylinder Compression Pressure:
Minimum 100 psi with no more than 25% variance between cylinders.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1012
Compression Check: Testing and Inspection
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions.
Ensure the battery is completely charged and the engine starter motor is in good operating
condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traffic and other forms of congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators: fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For Direct
Ignition System, disconnect the coil connector.
5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage. Record
this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than
(689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended compression pressures are to be used only as a guide
to diagnosing engine problems. An engine should not be disassembled to determine the cause of
low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test
resistance of spark plug cables. Refer to Powertrain Management. 13. Test coil output voltage,
primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at
idle and different RPM ranges.
Refer to Powertrain Management for Specifications.
15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation
system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and
therefore does not require adjustment.
See "Rocker Arm: Service and Repair" for further information.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage
Drive Belt: Customer Interest A/C Compressor - Locks Up At Low Mileage
Number: 24-15-99
Group: Heating & A/C
Date: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED
AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE
1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Compressor Lock-Up At Low Mileage
OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either
working the compressor loose or replacing it.
MODELS:
1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager
(International Market) 1998 - **2000** (PL) Neon
NOTE:
THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH
AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE
OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE
ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR.
SYMPTOM/CONDITION:
The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing
a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN
THE COMPRESSOR HAS FAILED.
With the close internal clearances of a compressor operating in an R134A system, it is possible to
experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system
is inactive, the more likely the lock-up condition is to occur.
This condition is the result of normal refrigerant movement within the A/C system caused by
temperature differences between the various components (evaporator, condenser, compressor)
that "washes" the oil out of the compressor.
DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt
to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the
A/C system is turned off perform the Repair Procedure.
REPAIR PROCEDURE:
This bulletin involves determining the extent of A/C compressor lock-up and either working the
compressor loose or replacing it.
Before assuming the A/C compressor has failed and must be replaced, the following steps should
be taken.
1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the
A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate
the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate
the compressor is internally damaged and must be replaced, skip to step 7.
2. Turn the hub clockwise five complete revolutions and remove the tool.
3. Start the vehicle, turn on the A/C system, and run at idle.
4. Observe the A/C compressor and system for normal operation for both cool-down and noise
level standpoints.
5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and
testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system
to operate at idle for 5 minutes.
6. If acceptable performance continues throughout the five minutes, the compressor does not need
to be replaced, skip to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1024
7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the
procedure outlined in the appropriate Service Manual to replace the A/C compressor.
8. Inspect the drive belt for damage, replace it if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs.
24-10-01-93 Replace Compressor 1.2 Hrs.
FAILURE CODE: 07 - Binds, Sticks or Seized
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist
Drive Belt: Customer Interest Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1029
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1030
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1031
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage
Drive Belt: All Technical Service Bulletins A/C Compressor - Locks Up At Low Mileage
Number: 24-15-99
Group: Heating & A/C
Date: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED
AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE
1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Compressor Lock-Up At Low Mileage
OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either
working the compressor loose or replacing it.
MODELS:
1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager
(International Market) 1998 - **2000** (PL) Neon
NOTE:
THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH
AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE
OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE
ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR.
SYMPTOM/CONDITION:
The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing
a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN
THE COMPRESSOR HAS FAILED.
With the close internal clearances of a compressor operating in an R134A system, it is possible to
experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system
is inactive, the more likely the lock-up condition is to occur.
This condition is the result of normal refrigerant movement within the A/C system caused by
temperature differences between the various components (evaporator, condenser, compressor)
that "washes" the oil out of the compressor.
DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt
to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the
A/C system is turned off perform the Repair Procedure.
REPAIR PROCEDURE:
This bulletin involves determining the extent of A/C compressor lock-up and either working the
compressor loose or replacing it.
Before assuming the A/C compressor has failed and must be replaced, the following steps should
be taken.
1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the
A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate
the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate
the compressor is internally damaged and must be replaced, skip to step 7.
2. Turn the hub clockwise five complete revolutions and remove the tool.
3. Start the vehicle, turn on the A/C system, and run at idle.
4. Observe the A/C compressor and system for normal operation for both cool-down and noise
level standpoints.
5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and
testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system
to operate at idle for 5 minutes.
6. If acceptable performance continues throughout the five minutes, the compressor does not need
to be replaced, skip to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1037
7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the
procedure outlined in the appropriate Service Manual to replace the A/C compressor.
8. Inspect the drive belt for damage, replace it if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs.
24-10-01-93 Replace Compressor 1.2 Hrs.
FAILURE CODE: 07 - Binds, Sticks or Seized
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist
Drive Belt: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page
1042
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page
1043
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page
1044
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1045
Accessory Drive Belt-3.3/3.8L Engines
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1046
Drive Belt: Description and Operation
The accessory drive system utilizes two different style of drive belts. The conventional V-belt and
the Poly-V belt are used to drive the generator, air conditioning compressor, power steering pump
and water pump. Satisfactory performance of these belts depends on belt condition and proper belt
tension. Belt tensioning should be performed with the aid of a Belt Tension Gauge, Special Tool
7198. Because of space limitations in the engine compartment, the use of this gauge may be
restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the
drive belts, if necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1047
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1048
Drive Belt: Adjustments
Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt
tensioning should be performed with the aid of Special Tool 7198. Because of space limitations in
the engine compartment, the use of this gauge may be restricted. Raise the vehicle on a hoist and
the remove the splash shield to gain access to the drive belts, if necessary.
BELT TENSION GAUGE METHOD
Use belt tension gauge, Special Tool 7198.
Adjust belt tension for either a New or Used belt. For specifications, refer to Belt Tension Chart.
BELT TENSION CHART
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and
Installation
Drive Belt: Service and Repair Removal and Installation
A/C Belt
Refer to Drive Belt, Alternator for procedure.
Alternator Belt
Accessory Drive Belt-3.3/3.8L Engines
The Poly-V serpentine drive belt is provided with a dynamic tensioner to maintain proper belt
tension to drive the following components:
^ generator
^ power steering pump
^ air conditioning compressor
^ water pump
REMOVAL
1. Raise vehicle on hoist.
Accessory Drive Belt Splash Shield
2. Remove accessory drive belt splash shield.
WARNING: DO NOT ALLOW DRIVE BELT TENSIONER TO SNAP BACK, AS DAMAGE TO
TENSIONER AND/OR PERSONAL INJURY COULD RESULT.
3. Release belt tension by rotating the tensioner clockwise. 4. Remove drive belt.
INSTALLATION
1. Properly route and position belt onto all pulleys, except for the tensioner pulley. 2. Rotate belt
tensioner clockwise until belt can be installed onto the tensioner pulley. Slowly release belt
tensioner. 3. Verify belt is properly routed and engaged on all pulleys.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and
Installation > Page 1051
4. Install splash shield and lower vehicle.
Power Steering Belt
Refer to Drive Belt, Alternator for procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and
Installation > Page 1052
Drive Belt: Service and Repair Cleaning and Inspection
Serpentine Drive Belt Wear Patterns
When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt
from rib to rib, are considered normal. These are not reasons to replace the belt. However, cracks
running along the rib (not across) are not normal. Any belt with cracks running along the rib must
be replaced. Also replace the belt if it has excessive wear, frayed cords, or severe glazing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Page 1053
Belt Tension Gauge 7198
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair
Air Filter Element: Service and Repair
REMOVAL
Air Inlet Resonator
1. Remove 2 screws and air inlet resonator. 2. Loosen 3 clamps holding air cleaner housing halves
together.
Air Cleaner Housing (Left Side)
3. Remove left side of air cleaner housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair > Page 1059
Air Cleaner Element
4. Remove element from air cleaner housing.
INSTALLATION
1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4.
Install hoses and air inlet resonator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and
Operation
Crankcase Filter: Description and Operation
OPERATION
All engines use filtered air to vent the crankcase. The filtered air is drawn through the resonator
assembly located between the air cleaner and throttle body.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair
Fluid Filter - A/T: Service and Repair
NOTE: Refer to Maintenance, or the vehicle owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at the time of the transmission oil change. The
magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2.
Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body and tighten
retaining screws to 5 Nm (40 inch lbs.). 4. Clean the oil pan and magnet. Reinstall pan using new
MOPAR Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four
quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening.
6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
Fig. 8
7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to
3 mm (1/8 inch) below the "ADD" mark on the
dipstick.
TRANSMISSION FLUID TEMPERATURE CHART
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Page 1066
8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 9.
To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick
opening
ALTERNATIVE SERVICE METHODS (FLUID ONLY)
TRANSAXLE FLUID EXCHANGER METHOD
CAUTION The use of any fluid exchanger that introduces additives into the transaxle is not
recommended.
1. To perform the transaxle fluid exchange, the transaxle must be at operating temperature. Drive
the vehicle until it reaches full operating
temperature.
2. Obtain a suitable transaxle fluid exchanger and verify the tank is clean and dry. 3. Fill the tank to
the recommended fill capacity with MOPAR ATF+4 Type 9602. 4. Connect the machine to the
vehicle following the manufacturers instructions. Perform the exchange procedure following the
instructions provided
with the machine.
5. Once machine has completed the fluid exchange. Check the fluid level and condition and fill to
proper level with MOPAR ATF+4 Type 9602.
Refer to Fluid Level and Condition Check for the proper fluid "top-off" procedure.
NOTE: Verify that the transaxle cooler lines are tightened to proper specifications. Cooler line
torque specification is 2 Nm (18 inch lbs.).
DIPSTICK TUBE FLUID SUCTION METHOD 1. When performing the fluid suction method, make
sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (macular or equivalent). 3. Insert the fluid suction line
into the dipstick tube.
NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5.
Remove the suction line from the dipstick tube. 6. Pour four quarts of MOPAR ATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at
least one minute. Then, with parking and service brakes applied, move selector lever momentarily
to each
position, ending in the park or neutral position.
8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to
3 mm (1/8 inch) below the "ADD" mark on the
dipstick.
9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.).
10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the
dipstick opening.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions
Fuel Pressure Release: Service Precautions
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions > Page 1071
Fuel Pressure Release: Service and Repair
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap.
Fuel Pressure Test Port
Releasing Fuel Pressure
3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel
pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other
end of hose C-4799-1 to
fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container.
Fuel gauge C-4799-B contains hose C-4799-1.
5. Replace Pressure test port cap when finished doing pressure test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Service and
Repair
Fuel Pump Pickup Filter: Service and Repair
REMOVAL
1. Remove fuel pump module. Refer to Fuel Pump Module Removal.
Inlet Strainer Removal
2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and
remove the strainer. 3. Remove strainer O-ring from the fuel pump reservoir body. 4. Remove any
contaminants in the fuel tank by washing the inside of the fuel tank.
INSTALLATION
1. Lubricate the strainer O-ring with clean engine oil. 2. Insert strainer O-ring into outlet of strainer
so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump
reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the
strainer.
4. Install fuel pump module. Refer to Fuel Pump Module Installation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications
Oil Filter: Specifications
Oil Filter Bypass Valve Setting 9 - 15 psi
Oil Filter Type Full Flow
Oil Pressure Switch Actuating Pressure (Min.) 2 - 4 psi
Oil Filter Attaching Nipple 30 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page
1078
Oil Filter: Service and Repair
Oil Filter
CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the
remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can to
the base is reinforced by the base plate.
1. Using suitable oil filter wrench, turn filter counterclockwise to remove from base. Properly discard
filter. 2. Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new filter with
clean engine oil. 4. Install new filter until gasket contacts base. Tighten filter 1 turn or 20 Nm (15 ft.
lbs.). Use filter wrench if necessary. 5. Start engine and check for leaks.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair
Refrigerant Filter: Service and Repair
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION .
1. Recover A/C system refrigerant.
Filter-Drier Assembly
2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan
module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator
crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location.
INSTALLATION
1. Before installation , replace both refrigerant line O-rings. Then reverse the above procedures.
Torque filter/drier mounting bolts to 45 in. lbs. ± 10. 2. Evacuate and recharge system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair
Heater Hose: Service and Repair
REMOVAL
NOTE: Review Safety Precautions and Warnings before proceeding with this operation.
1. Drain engine cooling system.
Upper Heater Hose
Lower Heater Hose
2. Loosen clamps at each end of heater hose to be removed.
CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive
force. Heater core may become damaged and leak engine coolant.
3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the
hose will not come off, slice the hose at the
connector nipple and peel off heater hose. This method will require heater hose replacement.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > A/C Suction/Discharge Line - Service
Hose/Line HVAC: Technical Service Bulletins A/C Suction/Discharge Line - Service
NUMBER: 24-14-99
GROUP: Heating & A/C
DATE: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-11-98 REV. A, DATED
JULY. 24, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Suction And/Or Discharge Line Service
MODELS:
1996 - **2000** (NS) Town & Country/Caravan/Voyager 1996 - **2000** (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
DISCUSSION: It an A/C suction and/or discharge line requires replacement due to cracking at or
near the compressor, inspect the three (3) A/C compressor mounting bolts and be sure they are
torqued to 40 ft. lbs. (54 Nm).
The root cause of A/C suction and/or discharge line cracking at or near the compressor may be
related to the compressor being improperly secured to the engine. Excessive vibration may result if
the compressor attaching bolts are not properly torqued. This vibration will eventually crack the
aluminum tubing of the A/C lines and/or compressor mounting ears.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement
Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement
REMOVAL
1. Recover A/C system refrigerant.
Compressor Discharge Line
2. Remove discharge line mounting nut at compressor.
Condenser Discharge Line
3. Remove discharge line at the top fitting on the condenser.
INSTALLATION
1. For installation , reverse the above procedures. Replace all O-rings. Torque discharge line at
condenser bolt to 180 in. lbs. ± 10. 2. Evacuate and recharge A/C system. 3. Perform the HVAC
Control Calibration Diagnostic and Cooldown test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1092
Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement
REMOVAL
1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the
accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel.
A/C Refrigerant Line Plate
6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve.
Expansion Valve Stud And Mounting Screws
7. Remove the stud from the expansion valve. 8. Remove liquid line from expansion valve. 9.
Cover the openings to prevent contamination.
10. Disconnect wire connector at pressure transducer. 11. Remove liquid line mounting bracket at
right frame rail. 12. Using access slot between radiator crossmember and grille, loosen liquid line
mounting plate at filter-drier. Remove liquid line from filter-drier. It
may be necessary to bend liquid line in half to remove line. The replacement line is a two-piece
assembly.
13. Remove the old O-rings.
INSTALLATION
For installation, reverse the above procedures.
- Install the stud to the evaporator sealing plate and tighten 7 to 11 Nm (64 to 96 in. lbs.) torque.
- Install new O-rings.
- Install two-piece line in place of original part.
- Assemble line halves after it is installed on vehicle.
- Evacuate and recharge A/C system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1093
Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement
REMOVAL
1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the
accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel.
A/C Refrigerant Line Plate
6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve.
Expansion Valve Stud And Mounting Screws
7. Remove the stud from the expansion valve. 8. Remove suction line from expansion valve.
Suction Line At Compressor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1094
9. Remove suction line mounting nut at compressor.
10. Remove suction line mounting bracket. 11. Remove suction line.
INSTALLATION
For installation, reverse the above procedures.
- Install the stud to the evaporator sealing plate and tighten 7 to 11 Nm (64 to 96 in. lbs.) torque.
- Install new O-rings.
- Install two-piece line in place of original part.
- Assemble line halves after it is installed on vehicle.
- Evacuate and recharge A/C system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1095
Hose/Line HVAC: Service and Repair Refrigerant Line Replacement
Rear Air Conditioning Lines
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
REMOVAL
1. Hoist vehicle
Front Lines Connected To Rear Lines
2. Remove compression fittings to the suction and liquid lines located on the right, outboard side of
the underbody, rearward of the front
crossmember.
Rear A/C Block Connection
3. Remove (1) bolt securing A/C lines to block located on the right, outboard side of the underbody,
rearward of the rear wheel and tire.
Rear Heater And A/C Lines
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1096
4. Remove (3) straps securing underbody lines. 5. Separate and remove A/C lines from vehicle.
INSTALLATION
1. Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved
wax-free refrigerant oil. Then, reverse the above
procedures.
2. Evacuate and recharge system.
Rear Heater Lines
REMOVAL
NOTE: Review Safety Precautions and Warnings before proceeding with this operation.
1. Partially drain engine cooling system.
Front Lines Connected To Rear Lines
2. Loosen clamp at the front end of the hose located at the right, outboard side of the underbody,
rearward of the front crossmember. 3. Carefully rotate hose back and forth while tugging slightly
away from connector nipple. If the hose will not come off, slice the hose at the
connector nipple and peel off heater hose. This method will require heater hose replacement.
CAUTION: When removing hoses from outlet nipples, do not use excessive force. Outlet nipples
may become damaged and leak engine coolant.
Rear Heater Hose Quick Connects
4. Compress insert in rear heater hose quick connection and pull downward on hose.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1097
Rear Heater And A/C Lines
5. Remove (3) straps securing underbody lines. 6. Separate and remove rear heater lines from
vehicle.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1106
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1107
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1108
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1109
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1110
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1111
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1117
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1118
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1119
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1120
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1121
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1122
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Page 1123
Power Steering Line/Hose: Specifications
Hose Tube Nuts ...................................................................................................................................
................................................ 31 Nm (275 inch lbs.) Routing Bracket To Suspension Cradle
.................................................................................................................................................... 28
Nm (21 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Page 1124
Power Steering Line/Hose: Description and Operation
Power Steering Hoses
The power steering fluid hoses connect the components of the power steering system. They
transfer fluid from one component to the next. The power steering fluid supply hose is a formed
hose that connects the power steering fluid reservoir to the power steering pump. It is secured at
both ends using standard adjustable clamps. The power steering fluid pressure hose is a high
pressure hose that connects the power steering pump to the gear. At both ends of the flexible hose
portion are steel fittings that are pressure crimped to the flexible hose. A standard tube nut fitting
with an O-ring is used at both ends to connect the components. The power steering fluid return
hose is a formed metal and rubber hose that connects the gear back to the power steering pump. A
standard tube nut fitting with an O-ring is used to connect it to the gear. It is secured to the power
steering pump using a standard adjustable clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump
Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump
REMOVE
Fluid Supply Hose At Power Steering Fluid Reservoir
1. Remove the filler cap from remote power steering fluid reservoir. 2. Using a siphon pump,
remove as much power steering fluid as possible from the power steering fluid reservoir.
Power Steering Fluid Hose Routing Clip
3. Remove power steering fluid supply hose routing clip from stud in strut tower. 4. Raise vehicle
on jack stands or centered on a frame contact type hoist. 5. Remove at power steering pump, the
power steering fluid hose coming from the power steering fluid reservoir. Let the power steering
fluid drain
out of the reservoir and hose.
6. Lower vehicle. 7. Remove hose clamp attaching the power steering fluid supply hose to the
power steering fluid reservoir. 8. Remove the power steering fluid supply hose from the vehicle.
Hose is removed from the top of the engine compartment.
INSTALL
CAUTION: On V-6 engine applications, the power steering fluid reservoir to power steering hose
must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed
under the wiring harness and below the drip tube. This routing will prevent the power steering fluid
supply hose from coming in contact with the accessory drive belt.
1. Install and correctly route the power steering fluid supply hose from remote fluid reservoir down
to power steering pump. 2. Install the fluid supply hose onto the power steering fluid reservoir.
Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed
past bead on fluid reservoir fitting.
3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Install power steering
fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose. Be sure
hose clamp is installed
past bead on pump fitting.
5. Lower vehicle. 6. Install routing clip on power steering fluid supply hose. Be sure routing clip is
installed in a position to correctly align with stud in strut tower.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump > Page 1127
7. Install routing clip for power steering fluid supply hose on stud in strut tower. 8. Fill the remote
fluid reservoir to the proper level and let the fluid settle for at least two minutes. 9. Start the engine
and let run for a few seconds. Then turn the engine off.
10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after
running the engine. 11. Raise the front wheels off the ground. 12. Start the engine. Slowly turn the
steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if
necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the
engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the
vehicle to stand a few minutes and repeat the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump > Page 1128
Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose
Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power
steering pump fittings and steering gear ports to prevent entry of foreign material into the
components.
WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY
LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST
MANIFOLD OR CATALYST.
For part reference and part location for the vehicle that is being serviced, refer to the illustrations.
These show the hose bracket locations, hose routings and fitting locations by the engine
application of the vehicle. Use these images when referring to the removal or installation
procedures for the power steering hoses listed below.
REMOVE
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil
drain pan under vehicle to catch power steering fluid.
4. Raise the heat sleeve on the power steering fluid return hose to expose the return hose to steel
tube connection. Remove the hose clamp from the
power steering fluid return hose. Remove power steering fluid return hose from steel tube and
allow power steering fluid to drain from pump.
Pressure Hose Connection To Power Steering Pump
5. Remove the power steering fluid pressure line from the power steering pump pressure fitting.
Drain excess power steering fluid from hose.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump > Page 1129
6. Remove bolt, attaching power steering hose routing bracket to front suspension cradle.
7. Disconnect power steering hose at power steering gear assembly. Drain the power steering fluid
from power steering pump and hose. 8. Discard the O-rings on the ends of power steering fluid
pressure hose.
INSTALL
1. Using a lint free towel, wipe clean the open power steering hose ends, power steering pump
pressure fitting and steering gear ports. 2. Install new O-rings on the ends of the power steering
fluid pressure hose. Lubricate O-rings using clean power steering fluid. 3. Attach the power
steering pressure hose to the fittings on the power steering pump and steering gear. Route hose
avoiding tight bends or kinking.
Do not bend tube ends of the power steering hoses when installing.
4. Install the power steering fluid hoses to suspension cradle routing bracket. Power steering fluid
hoses must remain away from the exhaust system
and must not come in contact with any unfriendly surfaces of the vehicle.
CAUTION: When tightening and torquing the pressure hose at the power steering pump, the
pressure hose is to be rotated against the fluid return hose fitting on the pump.
5. Tighten all fasteners shown for specific applications to their correct torques listed below:
- Pump End Tube Nut 34 Nm (25 ft. lbs.)
- Gear End Tube Nut 34 Nm (25 ft. lbs.)
- Pump Bracket Nut 40 Nm (30 ft. lbs.)
6. Install the power steering fluid return hose on the steel tube at the front suspension cradle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump > Page 1130
7. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 Nm (18 inch. lbs.).
CAUTION: The protective heat sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses.
8. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses
to keep them in their proper position.
9. After hoses are installed and power steering system is filled with fluid and cap is installed on
reservoir. Start the engine and check for leaks.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump > Page 1131
Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose
Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power
steering pump fittings and steering gear ports to prevent entry of foreign material into the
components.
WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY
LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST
MANIFOLD OR CATALYST.
For part reference and part location for the vehicle that is being serviced, refer to the images.
These show the hose bracket locations, hose routings and fitting locations by the engine
application of the vehicle.
REMOVE
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil
drain pan under vehicle to catch power steering fluid.
4. Raise the insulating heat sleeve on the power steering hoses to expose the hose to steel tube
connection. Remove hose clamp where rubber portion
of power steering fluid return hose attaches to steel tube on suspension cradle. Remove rubber
hose from steel tube and allow power steering fluid to drain from pump.
5. Remove the power steering fluid return hose from the power steering pump return hose fitting.
INSTALL
1. Using a lint free towel, wipe clean the open power steering hose ends and power steering pump
fitting. 2. Attach the power steering return hose to the fitting on the power steering pump. Route
hose smoothly avoiding tight bends or kinking. Hose must
remain away from the exhaust system and not come in contact with any unfriendly surfaces of the
vehicle.
3. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 4.
Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 Nm (18 inch. lbs.).
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses. This is to prevent
overheating of the power steering fluid hoses.
5. When used, position the protective heat sleeves on the power steering hoses so they cover the
connection to the power steering pump. Then, tie
strap the heat sleeves to the power steering hoses to keep them in their proper position.
6. After hoses are installed and power steering system is filled with fluid and cap is installed on
reservoir. Start the engine and check for leaks.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Description and Operation
Radiator Hose: Description and Operation
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING
ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND
WITHOUT PUSHING DOWN ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW
FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS
PUSHING OUT COOLANT AND STEAM AND THE PRESSURE DROPS CONTINUE SERVICE.
WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM
HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING
THIS TYPE OF CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT
TENSION CLAMPS.
Spring Clamp Size Location
CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If
replacement is necessary, use only a original equipment clamp with matching number or letter.
Hose Clamp Tool
The hose clamps are removed by using Special Tool 6094 or equivalent constant tension clamp
pliers to compress hose clamp.
A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet
and outlet when loosening hoses.
Radiator hoses should be routed without any kinks and indexed as designed. The use of molded
hoses is recommended.
Make sure hoses and connectors are clean and dry before installation. Do not lubricate hoses
when installing.
Spring type hose clamps are used in all applications. If replacement is necessary, replace with the
original Mopar(R) equipment spring type clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
BRAKE FLUID
Specification ........................................................................................................................................
.................................................................. DOT 3
Standard ..............................................................................................................................................
........................................................... SAE J1703
NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703
standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake
system. Use only Mopar brake fluid or an equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An
open container of brake fluid will absorb moisture from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission
fluid, power steering fluid, etc.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1139
Brake Fluid: Service Precautions
SAFETY PRECAUTIONS
WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following
actions:
* Eye Contact-rinse eyes thoroughly with water.
* Skin Contact-wash skin with soap and water.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1140
Brake Fluid: Testing and Inspection
CAUTION:
The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic
fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid
absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the
vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake
fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an
equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid
separates into layers, there is mineral oil or other fluid contamination of the brake fluid.
If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the
rubber parts or components containing rubber coming into contact with the brake fluid. This
includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS
hydraulic control unit (HCU), and all hydraulic fluid hoses.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1141
Brake Fluid: Service and Repair
MASTER CYLINDER FLUID LEVEL CHECK
Check master cylinder reservoir fluid level a minimum of twice annually.
Master Cylinder Fluid Level Marks
Master cylinder reservoirs are marked with the words FULL and ADD to indicate proper brake fluid
fill level of the master cylinder.
If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the
master cylinder fluid reservoir. When filling master cylinder fluid reservoir do not fill the filler neck of
the fluid reservoir with brake fluid.
Use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to
DOT 3 specifications.
Do not use brake fluid with a lower boiling point, as brake failure could result during prolonged hard
braking.
Use only brake fluid that was stored in a tightly sealed container.
Do not use petroleum-based fluid because seal damage will result. Petroleum based fluids would
be items such as engine oil, transmission fluid, power steering fluid etc.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
COOLING SYSTEM CAPACITY
2.0L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
............................................ 10.6 L (11.23 qts) Rear Heater ...............................................................
............................................................................................................................................. N/A
Trailer Tow
Front Heater ........................................................................................................................................
.................................................................. N/A Rear Heater ...............................................................
............................................................................................................................................. N/A
3.0L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
.............................................. 12.3 L (13.0 qts) Rear Heater ...............................................................
............................................................................................................................................. N/A
Trailer Tow
Front Heater ........................................................................................................................................
.............................................. 12.3 L (13.0 qts) Rear Heater ...............................................................
........................................................................................................................ 15.0 L (15.9 qts)
3.3/3.8L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
............................................ 12.5 L (13.23 qts) Rear Heater ...............................................................
.................................................................................................................... 15.26 L (16.13 qts)
Trailer Tow
Front Heater ........................................................................................................................................
............................................ 12.5 L (13.23 qts) Rear Heater ...............................................................
.................................................................................................................... 15.26 L (16.13 qts)
NOTE: Capacities include heater and coolant recovery tank filled to Max level.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 1146
Coolant: Fluid Type Specifications
The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle
operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide
protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a
minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be
eroded by cavitation, and cooling system components may be severely damaged by corrosion.
Maximum protection against freezing is provided with a 68% antifreeze concentration, which
prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer
temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the
specific heat of antifreeze is lower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used
Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the
corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The
deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this
temperature is hot enough to melt plastic and soften solder. The increased temperature can result
in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F).
Propylene-Glycol Formulations Should Not Be Used
Propylene-glycol formulations do not meet the required specifications. It's overall effective
temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point.
The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at
96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can
result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics
than ethylene-glycol. This can increase cylinder head temperatures under certain conditions.
Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used
Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion
inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and
propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the
freeze point will not be accurate. Both the refractive index and specific gravity differ between the
ethylene-glycol and propylene-glycol.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can
cause problems associated with 100 percent ethylene-glycol.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1147
Coolant: Service Precautions
DO NOT mix green colored coolant with orange colored coolant.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation >
Description and Operation
Coolant: Description and Operation
The cooling system is designed around the coolant. The coolant must accept heat from engine
metal, in the cylinder head area near the exhaust valves. Coolant then carries this heat to the
radiator, where the tube/fin assemblies of these components can give it up to the air.
The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion
protection. Mopar(R) Antifreeze or the equivalent is recommended for best engine cooling without
corrosion, when mixed only to a freeze point of -37°C (-35°F) to -5C (-50F). If it loses color or
becomes contaminated, drain, flush, and replace with fresh properly mixed solution.
CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene
glycol and distilled water mix is recommended.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation >
Description and Operation > Page 1150
Coolant: Description and Operation Coolant Performance
Performance is measurable. For heat transfer pure water excels (Formula = 1 btu per minute for
each degree of temperature rise for each pound of water). This formula is altered when necessary
additives to control boiling, freezing, and corrosion are added as follows: ^
Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F).
^ 100 percent Glycol (.7 btu) can cause a hot engine and detonation and will lower the freeze point
to -22°C (-8°F).
^ 50/50 Glycol and Water (.82 btu) is the recommended combination that provides a freeze point of
-37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat,
temperature gauge, sending unit and heater are all designed for 50/50 glycol.
CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene
glycol and distilled water mix is recommended.
Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of
-59°C (-50°F).
CAUTION: Richer mixtures cannot be measured with field equipment. This can lead to problems
associated with 100 percent glycol.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page
1151
Coolant: Testing and Inspection
Coolant concentration should be checked when any additional coolant was added to system or
after a coolant drain, Rush and refill. The coolant mixture offers optimum engine cooling and
protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -59°C (-50°F). The
use of a hydrometer or a refractometer can be used to test coolant concentration.
Hydrometers test the amount of glycol in a mixture by measuring the specific gravity of the mixture.
The higher the concentration of ethylene glycol, the larger the number of balls that will float, and
higher the freeze protection (up to a maximum of 70% by volume glycol).
Refractometers test the amount of glycol in a coolant mixture by measuring the amount a beam of
light bends as it passes through the fluid.
Some coolant manufactures use other types of glycols into their coolant formulations. Propylene
glycol is the most common new coolant. However, propylene glycol based coolants do not provide
the same freezing protection and corrosion protection and is only recommended for limited usage.
Refer to appropriate Technical Service Bulletin(s) regarding use of propylene glycol based
coolants.
CAUTION: Do not mix types of coolant. Corrosion protection will be severely reduced.
Because ethylene glycol and propylene glycol do not have the same specific gravities, the use of a
hydrometer will be inaccurate. Therefore, Special Tool 8286 refractometer, must be used when
testing coolant.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page
1152
Coolant: Service and Repair
Refer to Cooling System, Service and Repair for applicable service procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
A/T - ATF+4 Fluid Usage/Applications
Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications
NUMBER: 21-010-06
GROUP: Transmission
DATE: April 14, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH
16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE
REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602)
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1989 - 2003 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AD) Ram Truck
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2004 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1990 - 1991 (AQ) Maserati
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2003 (BR/BE) Ram Truck
2004 - 2007 (CS) Pacifica
1998 - 2003 (DN) Durango
2002 - 2007 (DR/DH/D1) Ram Truck
2007 (DC) Ram 3500 Cab Chassis
1995 - 2000 (FJ) Sebring/Avenger/Talon
1996 - 2000 (CS) Chrysler Voyager (International Market)
2004 - 2007 (HB) Durango
1995 - 2000 (JA) Cirrus/Stratus/Breeze
2007 (JK) Wrangler
2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
A/T - ATF+4 Fluid Usage/Applications > Page 1157
2007 (JS) Avenger/Sebring
1996 - 2000 (JX) Sebring Convertible
2002 - 2007 (KJ) Liberty
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M
2005 - 2007 (LX/LE) 300/Magnum/Charger
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2005 (PL) Neon
2002 - 2003 (PG) PT Cruiser (International Markets)
2001 - 2007 (PT) PT Cruiser
1997 - 2002 (PR) Prowler
2001 - 2007 (RG) Chrysler Voyager (International Markets)
2001 - 2007 (RS) Town & Country/Caravan/Voyager
1997 - 2006 (TJ) Wrangler
2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines
1999 - 2004 (WJ) Grand Cherokee
2005 - 2007 (WK/WH) Grand Cherokee
2006 - 2007 (XK/XH) Commander
1989 - 1995 (YJ) Wrangler
1996 - 1998 (ZG) Grand Cherokee (International Markets)
1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire
transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG
vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission
(sales code DGJ).
DISCUSSION:
ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions.
ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions
EXCEPT FOR THOSE NOTED ABOVE.
NOTE:
ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE
ANY OTHER FLUID.
NOTE:
ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be
used to top off vehicles that used ATF+3, ATF+2, or ATF+.
NOTE:
If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid
maintenance schedules listed for that model does not change. The service interval currently in
effect for a given model should continue to be followed. Refer to the Service or Owners manual for
maintenance schedule directions.
In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to
use ATF+4.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
A/T - ATF+4 Fluid Usage/Applications > Page 1158
BENEFITS
^ Better anti-wear properties
^ Improved rust/corrosion prevention
^ Controls oxidation
^ Eliminates deposits
^ Controls friction
^ Retains anti-foaming properties
^ Superior properties for low temperature operation
FLUID COLOR
Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not
permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a
unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer
indicators of fluid condition and do not necessarily support a fluid change.
PARTS REQUIRED:
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid
31TH ....................................................................................................................................................
............................................................. 8.0L (8.5 Qt) 41TE .................................................................
................................................................................................................................................ 8.6L
(9.1 Qt)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 1161
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type Type ............................................................................................................
....................................................... MOPAR ATF +4 Type 9602 or Equivalent
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1162
Fluid - A/T: Service Precautions
DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission
damage may occur.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level and Condition Check
Fluid - A/T: Service and Repair Fluid Level and Condition Check
NOTE: The transmission and differential utilize the same fluid sump, which require Automatic
Transmission Fluid (ATF+4/Type 9602).
NOTE: The transmission fluid level should be inspected at least every six months.
FLUID LEVEL CHECK
The transmission sump has a dipstick to check oil similar to most automatic transmissions. It is
located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing.
Fig. 7
The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P
Park to be sure that the fluid level check is accurate. The engine should be running at idle speed
for at least one minute, with the vehicle on level ground. At normal operating temperature
(approximately 82°C or 180°F), the fluid level is correct if it is in the HOT region (cross-hatched
area) on the oil level indicator (Fig. 7). The fluid level will be approximately one-quarter inch above
the lower hole of the dipstick at 70°F fluid temperature.
FLUID LEVEL CHECK USING DRB
NOTE: Engine and Transaxle should be at normal operating temperature before performing this
procedure.
1. Start engine and apply parking brake. 2. Hook up DRBIII scan tool and select transmission. 3.
Select sensors. 4. Read the transmission temperature value. 5. Compare the fluid temperature
value with the chart.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level and Condition Check > Page 1165
TRANSMISSION FLUID TEMPERATURE CHART
6. Adjust transmission fluid level shown on the dipstick according to the chart. 7. Check
transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump
to take in air along with the fluid. As in
any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build
up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much
fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In
either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid
escaping from the transaxle vent where it may be mistaken for a leak. Along with fluid level, it is
important to check the condition of the fluid. When the fluid smells burned, and is contaminated
with metal or friction material particles, a complete transaxle recondition is needed. Be sure to
examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a
sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water
and dirt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level and Condition Check > Page 1166
Fluid - A/T: Service and Repair Fluid and Filter Service
NOTE: Refer to Maintenance, or the vehicle owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at the time of the transmission oil change. The
magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2.
Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body and tighten
retaining screws to 5 Nm (40 inch lbs.). 4. Clean the oil pan and magnet. Reinstall pan using new
MOPAR Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four
quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening.
6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
Fig. 8
7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to
3 mm (1/8 inch) below the "ADD" mark on the
dipstick.
TRANSMISSION FLUID TEMPERATURE CHART
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level and Condition Check > Page 1167
8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 9.
To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick
opening
ALTERNATIVE SERVICE METHODS (FLUID ONLY)
TRANSAXLE FLUID EXCHANGER METHOD
CAUTION The use of any fluid exchanger that introduces additives into the transaxle is not
recommended.
1. To perform the transaxle fluid exchange, the transaxle must be at operating temperature. Drive
the vehicle until it reaches full operating
temperature.
2. Obtain a suitable transaxle fluid exchanger and verify the tank is clean and dry. 3. Fill the tank to
the recommended fill capacity with MOPAR ATF+4 Type 9602. 4. Connect the machine to the
vehicle following the manufacturers instructions. Perform the exchange procedure following the
instructions provided
with the machine.
5. Once machine has completed the fluid exchange. Check the fluid level and condition and fill to
proper level with MOPAR ATF+4 Type 9602.
Refer to Fluid Level and Condition Check for the proper fluid "top-off" procedure.
NOTE: Verify that the transaxle cooler lines are tightened to proper specifications. Cooler line
torque specification is 2 Nm (18 inch lbs.).
DIPSTICK TUBE FLUID SUCTION METHOD 1. When performing the fluid suction method, make
sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (macular or equivalent). 3. Insert the fluid suction line
into the dipstick tube.
NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5.
Remove the suction line from the dipstick tube. 6. Pour four quarts of MOPAR ATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at
least one minute. Then, with parking and service brakes applied, move selector lever momentarily
to each
position, ending in the park or neutral position.
8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to
3 mm (1/8 inch) below the "ADD" mark on the
dipstick.
9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.).
10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the
dipstick opening.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Oil Capacity
Capacity ...............................................................................................................................................
......................................................... 1.9L (4.0 Pints)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications > Page 1172
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Grade ...................................................................................................................................................
................................................................... API GL-5
Viscosity ..............................................................................................................................................
..................................................................... 80W-90
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page
1173
Fluid - Differential: Service Precautions
DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Power Transfer Unit .............................................................................................................................
........................................................ 1.2L (2.4 Pints)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 1178
Fluid - Transfer Case: Fluid Type Specifications
Power Transfer Unit
Viscosity ..............................................................................................................................................
.............................................................. SAE 85W-90
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Page 1179
Fluid - Transfer Case: Service Precautions
DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil
Without Filter Change ..........................................................................................................................
............................................................. 3.8L (4.0 Qt)
Capacity shown is without filter. When replacing filter, additional oil may be needed.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 1184
Engine Oil: Fluid Type Specifications
Engine Oil
API Classification .................................................................................................................................
........................................... SH or SH/CD or Above Above 0°F (-18°C)..............................................
........................................................................................................................................................
10W-30 Below 32°F (0°C)....................................................................................................................
..................................................................................... 5W-30
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1185
Engine Oil: Service Precautions
SAFETY PRECAUTIONS
WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer.
Avoid prolonged and repeated contact with oils, particularly used engine oils.
- Wear protective clothing, including impervious gloves where practicable.
- Do not put oily rags in pockets.
- Avoid contaminating clothes, particularly underpants, with oil.
- Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be
cleaned regularly.
- First Aid treatment should be obtained immediately for open cuts and wounds.
- Use barrier creams, applying them before each work period, to help the removal of oil from the
skin.
- Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help).
Preparations containing lanolin replace the natural skin oils which have been removed.
- Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin.
- If skin disorders develop, obtain medical advice without delay.
- Where practicable, degrease components prior to handling.
- Where there is a risk of eye contact, eye protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash facility should be provided.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Power Steering Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage
NUMBER: 19-005-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO
ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Power Steering Fluid Usage
MODELS:
1993 - 2003 (AB) Ram Van
1994 - 2004 (AN) Dakota
1994 - 2002 (BR/BE) Ram Pickup
2004 (CS) Pacifica
1998-2004 (DN) Durango
2002 - 2004 (DR) Ram Pickup
1996 - 2000 (GS) Chrysler Voyager (International Markets)
1995 - 2000 (JA) Cirrus/Stratus/Breeze
2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 - 2004 (KJ) Liberty
2002 - 2004 (KJ) Cherokee (International Markets)
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Voyager/Caravan
2002 (PG) Chrysler PT Cruiser (International Markets)
1995-2004 (PL) Neon
1997 - 2003 (PR) Prowler
2002 - 2004 (PT) Chrysler PT Cruiser
2001 - 2004 (RG) Chrysler Voyager (International Markets)
2001 - 2004 (RS) Town & Country/Caravan/Voyager
1993 - 2002 (SR) Viper/Viper Coupe
2001 - 2004 (ST) Sebring Coupe/Stratus Coupe
1997 - 2004 (TJ) Wrangler
2003 - 2004 (VA) Sprinter
1999 - 2004 (WG) Grand Cherokee (International Markets)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Power Steering Fluid Usage > Page 1190
1999-2004 (WJ) Grand Cherokee
2003 - 2004 (ZB) Viper
2004 (ZH) Crossfire
DISCUSSION:
The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4
(MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH
vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved
service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and
MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is
no longer an indication of fluid condition.
The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number
for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA.
MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On
some past models, MS9602 should be used as the replacement fluid. On these models, if a power
steering system is being serviced that results in a large fluid loss, such as a pump, hose or
gear/rack replacement, the complete system should be drained and filled with MS9602.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Power Steering Fluid Usage > Page 1191
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Power Steering Fluid Usage > Page 1192
NOTE:
This bulletin supersedes owner's and service manuals for the vehicles listed above that may state
to use MS9933 in the power steering system, and that may state not to use automatic transmission
fluid in the power steering system.
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications
Power Steering Fluid: Capacity Specifications
Power steering fluid 1.7 pt (US)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications > Page 1195
Power Steering Fluid: Fluid Type Specifications
All models Mopar Power Steering Fluid or equivalent
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Page 1196
Power Steering Fluid: Service Precautions
DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage
can result.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Page 1197
Power Steering Fluid: Service and Repair
WARNING: FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING PARTS.
CAUTION: Do not use automatic transmission fluid in the power steering system.
Before removing the power steering filler cap, wipe the reservoir filler cap free of dirt and debris.
Remove the cap and check the fluid level on its dipstick. The dipstick should indicate COLD when
the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F). Do not
overfill the power steering system. Use only Mopar Power Steering Fluid, or an equivalent.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
R134a Single Capacity ........................................................................................................................
........................................ 0.96 kg (34 oz. or 2.13 lbs)
R134a Dual Capacity ...........................................................................................................................
....................................... 1.36 kg (48 oz. or 3.00 lbs)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 1202
Refrigerant: Fluid Type Specifications
Hydrofluorocarbon (HFC), ...................................................................................................................
............................................... R-134a liquefied gas
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1203
Refrigerant: Description and Operation
This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear
colorless liquefied gas.
R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a
small amount of R-12 in a R-134a system could cause compressor failure, refrigerant oil to sludge
and/or poor performance. Never add any other type of refrigerant to a system designed to use
R-134a refrigerant. System failure will occur.
The high pressure service port is located on the liquid line near the strut tower. The low pressure
service port is located on the suction line near the compressor manifold.
Refrigerant Recovery/Recycling Station (Typical)
When servicing a system, it is required that an air conditioning charging recovery/recycling
machine be used. Contact an automotive service equipment supplier for proper equipment. Refer
to the operating instructions provided with the equipment for proper operation.
Manifold Gauge Set - Typical
A manifold gauge set must also be used in conjunction with the charging and/or recovery/recycling
device. Only use gauges that have not been used for R-12. The service hoses on the gauge set
should have manual (turn wheel) or automatic back flow valves at the service port connector ends.
This will prevent refrigerant R-134a from being released into the atmosphere.
R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure to use the
oil that is specified on the under hood label. Due to the different characteristics of R-134a it
requires all new service procedures.
The use of R-134a will have a positive environmental impact due to it's zero ozone depletion and
low global warming impact.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Front A/C Compressor .........................................................................................................................
............................................................ 150 ml 5.0 oz.
Dual A/C Compressor ..........................................................................................................................
............................................................ 220 ml 7.4 oz.
Dual A/C Evaporator ............................................................................................................................
.............................................................. 60 ml 2.0 oz.
Condenser ...........................................................................................................................................
................................................................ 30 ml 1.0 oz.
Evaporator ...........................................................................................................................................
............................................................... 60 ml 2.0 oz. Filter-Drier ......................................................
................................................................................................................................................... 30 ml
1.0 oz.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 1208
Refrigerant Oil: Fluid Type Specifications
Synthetic-based, Polyalkylene Glycol ..................................................................................................
.......................................................................... ND-8
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page
1209
Refrigerant Oil: Service and Repair
Refrigerant Oil Level Check
Refrigerant Oil Capacities
When an air conditioning system is first assembled, all components (except the compressor) are
refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil
in the compressor is dispersed through the lines and components. The evaporator, condenser, and
filter- drier will retain a significant amount of oil, refer to the Refrigerant Oil Capacities chart. When
a component is replaced, the specified amount of refrigerant oil must be added. When the
compressor is replaced, the amount of oil that is retained in the rest of the system must be drained
from the replacement compressor. when a line or component has ruptured and oil has escaped,
the compressor should be removed and drained. The filter-drier must be replaced along with the
ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining
components, can be measured and poured into the suction port of the compressor.
Example: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz)
of oil, and system capacity may be 220 ml (6.40 oz) of oil.
220 ml minus 90 ml = 130 ml (4.40 oz).
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG
(polyalkalene glycol).
Servicing Refrigerant Oil Level 1. Using a refrigerant recovery machine, remove refrigerant from
the A/C system. 2. Remove refrigerant lines from A/C compressor. 3. Remove compressor from
vehicle. 4. From suction port on top of compressor, drain refrigerant oil from compressor. 5. Add
system capacity minus the capacity of components that have not been replaced through suction
port on compressor. Refer to the
Refrigerant Oil Capacity Chart.
6. Install compressor, connect refrigerant lines, evacuate, and charge refrigerant system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake
System Bleeding Procedures
Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures
Bleeding Base Brake Hydraulic System
NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For
bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake
System bleeding procedure in antilock brakes.
Pressure Bleeding Procedure
CAUTION:
- Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid
reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid
reservoir.
- Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the
hydraulic system for bleeding.
- When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be
removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid
reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system
is pressurized.
Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment.
Air Trapped In Brake System
When bleeding the brake system, some air may be trapped in the brake lines or valves far
upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow
of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out.
1. Remove the filler neck from the master cylinder fluid reservoir.
Pressure Bleeding Cap Installed On Master Cylinder
2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the
fluid reservoir of the master cylinder. Attach the
fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent.
3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar
containing fresh brake fluid.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake
System Bleeding Procedures > Page 1214
adequate removal of all trapped air from the brake hydraulic system.
(1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel
Rear Wheel Cylinder Bleeder Screw
4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow
of brake fluid.
CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid
discharge will NOT get all the air out.
5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free
flow is maintained in the hose and jar, this will
indicate a good bleed of the hydraulic system has been obtained.
6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel.
If pedal travel is excessive or has not been
improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to
monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the
brake system through the master cylinder.
7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Bleeding Without A Pressure Bleeder
NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper.
NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must
be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are
correctly adjusted.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure adequate removal of all trapped air from the brake
hydraulic system.
- Left Rear Wheel
- Right Front Wheel
- Right Rear Wheel
- Left Front Wheel
1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened.
2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens
the brake pedal will drop all the way to the floor.
3. Release the brake pedal only after the bleeder screw is closed.
4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence.
This should pass a sufficient amount of fluid to expel
all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder,
so it stays at a proper level so air will not enter the brake system through the master cylinder.
5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake
System Bleeding Procedures > Page 1215
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
ANTILOCK BRAKE SYSTEM BLEEDING
The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS
though, particularly the ICU (HCU), should only be bled when the HCU is replaced or removed from
the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air.
Under most circumstances that require the bleeding of the brake hydraulic system, only the base
brake hydraulic system needs to be bled.
It is important to note that excessive air in the brake system will cause a soft or spongy feeling
brake pedal.
During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level
in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding
procedure and add DOT 3 brake fluid as required.
The ABS must be bled as two independent braking systems. The non-ABS portion of the brake
system with ABS is to be bled the same as any non-ABS system.
The ABS portion of the brake system must be bled separately. Use the following procedure to
properly bleed the brake hydraulic system including the ABS.
BLEEDING
When bleeding the ABS system, the following bleeding sequence must be followed to insure
complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure
or standard pressure bleeding equipment.
1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB scan
tool to the diagnostics connector. The diagnostic connector is located under the lower steering
column cover to the left of
the steering column.
3. Using the DRB, check to make sure the CAB does not have any fault codes stored. If it does,
clear them using the DRB.
WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR
BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A
CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF
BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE.
BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN
OPENED.
4. Bleed the base brake system using the standard pressure or manual bleeding procedure as
outlined in Base Brake Bleeding. 5. Using the DRB, select ANTILOCK BRAKES, followed by
MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When
the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed.
6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically
to prevent emptying, causing air to enter the
hydraulic system.
7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes
are operating correctly and that the brake pedal does not feel spongy.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS
.
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Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
Negative Battery Cable
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering
column and at the lower edge of the lower instrument
panel.
2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the
proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative
terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and
record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any
diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper
Body
Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes
on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to
diagnose the problem.
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Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations
Fuse: Locations
For fuse location and identification, refer to Electrical Accessory Panel (Power Distribution Center)
and/or Fuse Block (Junction Block) Locations, Components.
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Fuse: Diagrams
Junction Block
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Junction Block Fuses
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Power Distribution Center
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Power Distribution Center Fuses
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Locations
Fuses
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Fuse Block: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Fuse Block: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Fuse Block: Connector Views
Junction Block
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Junction Block C1 (A)
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Junction Block C2 (B)
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Junction Block C3 (D)
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Junction Block C4 (C)
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Fuse Block: Electrical Diagrams
Except Chrysler
Junction Block -- Sheet 8w-12-8
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Junction Block -- Sheet 8w-12-9
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Junction Block -- Sheet 8w-12-10
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Junction Block -- Sheet 8w-12-11
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Junction Block -- Sheet 8w-12-12
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Junction Block -- Sheet 8w-12-13
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Diagrams > Diagram Information and Instructions > Page 1263
Junction Block -- Sheet 8w-12-14
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1264
Junction Block -- Sheet 8w-12-15
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1265
Junction Block -- Sheet 8w-12-16
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1266
Junction Block -- Sheet 8w-12-17
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1267
Junction Block -- Sheet 8w-12-18
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1268
Junction Block -- Sheet 8w-12-19
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1269
Junction Block -- Sheet 8w-12-20
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1270
Junction Block -- Sheet 8w-12-21
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1271
Junction Block -- Sheet 8w-12-22
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1272
Junction Block -- Sheet 8w-12-23
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1273
Junction Block -- Sheet 8w-12-24
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Diagram Information and Instructions > Page 1274
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
This vehicle does not have a Maintenance Reminder Light option.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR (CHECK ENGINE) LAMP-PCM OUTPUT
The PCM supplies the malfunction indicator (check engine) lamp on/off signal to the instrument
panel through the CCD Bus. The CCD Bus is a communications port. Various modules use the
CCD Bus to exchange information.
The Check Engine lamp comes on each time the ignition key is turned ON and stays on for 3
seconds as a bulb test.
The Malfunction Indicator Lamp (MIL) stays on continuously, when the PCM has entered a Limp-In
mode or identified a failed emission component. During Limp-in Mode, the PCM attempts to keep
the system operational. The MIL signals the need for immediate service. In limp-in mode, the PCM
compensates for the failure of certain components that send incorrect signals. The PCM substitutes
for the incorrect signals with inputs from other sensors.
If the PCM detects active engine misfire severe enough to cause catalyst damage, it flashes the
MIL.
At the same time the PCM also sets a Diagnostic Trouble Code (DTC). For signals that can trigger
the MIL (Check Engine Lamp) refer to the On-Board Diagnostics Chart.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Description and Operation
Oil Change Reminder Lamp: Description and Operation
This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Description and Operation > Page 1285
Oil Change Reminder Lamp: Service and Repair
This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component
Information > Testing and Inspection
Oil Level Warning Indicator: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical
Service Bulletins > Spare Tire - Winch Precautions
Spare Tire: Technical Service Bulletins Spare Tire - Winch Precautions
BULLETIN NUMBER: 22-01-00
GROUP: Wheels & Tires
DATE: Mar.24, 2000
SUBJECT: Spare Tire Winches
MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE: THIS BULLETIN DOES NOT APPLY TO 1999 TOWN & COUNTRY VEHICLES BUILT
PRIOR TO JULY 2, 1998.
DISCUSSION: Beginning November 1,1999, the spare tire winch that is installed during vehicle
assembly is determined by the size/type of spare tire the vehicle is built with. DO NOT switch the
size/type of spare tire a vehicle is equipped with unless the spare tire winch is the correct one for
the size/type of spare tire to be used. Replacement of the spare tire winch may be required.
The spare tire winches are equipped with a secondary locking mechanism that may not function
properly if a full size spare or T125 70D15 Compact Spare is stored on a T145 90D16 compact
spare winch or vise-versa.
The illustration shows the correct application and identification for 1999-2000 NS-vehicle spare tire
winches:
PARTS INFORMATION
CAUTION: DO NOT SWITCH THE SIZE/TYPE OF SPARE TIRE A VEHICLE IS EQUIPPED WITH
UNLESS THE SPARE TIRE WINCH IS CORRECT FOR THE NEW SIZE/TYPE OF SPARE TIRE
AS CALLED OUT IN THE TABLE ABOVE. REPLACEMENT OF THE SPARE TIRE WINCH MAY
BE REQUIRED.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical
Service Bulletins > Page 1295
Spare Tire: Description and Operation
The temporary spare tire is designed for emergency use only. The original tire should be repaired
and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH
when the temporary spare tire is in use on the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1304
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1305
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1306
TIRE/WHEEL MATCH MOUNTING
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1307
WHEEL RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1308
WHEEL BORE PILOT DIAMETERS
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1309
HUB WHEEL PILOT DIAMETER
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1310
HUB WHEEL PILOT RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1311
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1317
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1318
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1319
TIRE/WHEEL MATCH MOUNTING
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1320
WHEEL RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1321
WHEEL BORE PILOT DIAMETERS
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1322
HUB WHEEL PILOT DIAMETER
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1323
HUB WHEEL PILOT RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1324
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-01-98 > Mar > 98 > Aluminum Wheels - Special Balance
Weights
Wheels: All Technical Service Bulletins Aluminum Wheels - Special Balance Weights
NO: 22-01-98
GROUP: Tires & Wheels
DATE: Mar. 13, 1998
SUBJECT: Balance Weights For Aluminum Wheels
MODELS: 1998 - 1999 (LH) Concorde/Intrepid/LHS/300M 1998 - 1999 (NS) Town &
Country/Caravan/Voyager
DISCUSSION:
Beginning with the 1998 model year LH and NS vehicle aluminum wheels have a unique balance
weight retention flange. This balance weight retention flange requires the use of special low profile
balance weights. The new balance weights are made by Perfect Equipment Company LLC, and
are available through their distributors and subsequent automotive jobbers.
The "LH Type Balance Weights" are available in 1/4 oz. Increments through the major distributors
listed:
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 22-01-98 > Mar > 98 > Aluminum Wheels - Special Balance Weights
Wheels: All Technical Service Bulletins Aluminum Wheels - Special Balance Weights
NO: 22-01-98
GROUP: Tires & Wheels
DATE: Mar. 13, 1998
SUBJECT: Balance Weights For Aluminum Wheels
MODELS: 1998 - 1999 (LH) Concorde/Intrepid/LHS/300M 1998 - 1999 (NS) Town &
Country/Caravan/Voyager
DISCUSSION:
Beginning with the 1998 model year LH and NS vehicle aluminum wheels have a unique balance
weight retention flange. This balance weight retention flange requires the use of special low profile
balance weights. The new balance weights are made by Perfect Equipment Company LLC, and
are available through their distributors and subsequent automotive jobbers.
The "LH Type Balance Weights" are available in 1/4 oz. Increments through the major distributors
listed:
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Page 1334
Wheels: Description and Operation
Original equipment wheels are designed for proper operation at all loads up to the specified
maximum vehicle capacity.
All models use steel or aluminum drop center wheels. Every wheel has raised sections between
the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead
over these raised sections. In case of air loss the raised sections hold the tire in position on the
wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special
balance weights to fit on the thicker flange of the rim and special wheel clamps for the alignment
equipment. The wheel studs and nuts are designed for the specific wheel applications used on a
vehicle and must be replaced with equivalent parts. Do not use replacement parts of lesser quality
or of a substitute design from the original equipment part. All aluminum wheels have wheel stud
nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the
wheels. Vehicles that are equipped with bolt-on wheel covers use large nose wheel nuts. The
wheel nuts used on a vehicle equipped with bolt-on wheel covers are externally threaded so that
the wheel covers can be attached to the wheel nuts. Before installing a wheel, remove any buildup
of corrosion on the wheel mounting surface.
WARNING: INSTALLING WHEELS WITHOUT GOOD METAL-TO-METAL CONTACT COULD
CAUSE LOOSENING OF WHEEL LUG NUTS. THIS COULD ADVERSELY AFFECT THE
SAFETY AND HANDLING OF YOUR VEHICLE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Page 1335
Wheels: Testing and Inspection
Wheels must be replaced if they: Have excessive run out
- Are bent, dented or cracked
- Leak air
- Have damaged wheel lug holes
Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Original
equipment replacement wheels are available through the dealer. When obtaining replacement
wheels from any other source, they must be equivalent in load carrying capacity. The wheel
features (diameter, width, offset, brake clearance, and mounting configuration) must match the
original equipment wheels.
WARNING: FAILURE TO USE ORIGINAL EQUIPMENT REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF YOUR VEHICLE.
- REPLACEMENT WITH USED WHEELS IS NOT RECOMMENDED. THE SERVICE HISTORY
OF THE RIM MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE
RIM COULD FAIL WITHOUT WARNING.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
Wheel Bearing: Specifications Lubricant Type
Lubricant Type
Wheel Bearing Grease NLGI GC rated automotive grease
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
FRONT:
To Hub Bearing Nut .............................................................................................................................
............................................ 183 Nm (135 ft. lbs.)
REAR:
Stub Axle Nut .......................................................................................................................................
............................................ 224 Nm (180 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
> Wheel Tightening Sequence
Wheel Fastener: Specifications Wheel Tightening Sequence
Wheel Torque Sequence - Master
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
> Wheel Tightening Sequence > Page 1347
Wheel Fastener: Specifications Lug Nut Torque
Lug Nut Torque ....................................................................................................................................
................................ 110 - 135 Nm (85 - 115 ft. lbs.) Hex Size ...........................................................
...........................................................................................................................................................
19 mm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
> Wheel Tightening Sequence > Page 1348
Wheel Fastener: Specifications Wheel Stud Size
Mounting Stud Size .............................................................................................................................
........................................................... M12 x 1.5 mm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front
Wheel Fastener: Service and Repair Front
REMOVAL
CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the
studs CANNOT be hammered out of the hub flange. If a stud is removed by hammering it out of the
bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing
failure.
The following procedure and special tools shown MUST BE used when replacing wheel attaching
studs. The hub and bearing assembly does not require removal from the steering knuckle to
replace wheel attaching studs in the hub and bearing assembly. 1. Raise vehicle on jackstands or
centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the
vehicle.
Disc Brake Caliper Mounting
3. Remove the front caliper assembly from the front steering knuckle assembly.
4. Remove front rotor from hub, by pulling it straight off wheel mounting studs. 5. Install a lug nut on
the wheel stud to be removed from the hub and bearing assembly, so the threads on the stud are
even with end of lug nut.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1351
Wheel Stud Removal From Hub/Bearing Assembly
Install Remover, Special Tool C-4150A on hub and bearing assembly flange and wheel stud. 6.
Tightening down on special tool will push wheel stud out of the hub and bearing assembly flange.
When shoulder of wheel stud is past flange
remove special tool from hub and bearing assembly. Remove lug nut from stud and remove wheel
stud from flange.
INSTALLATION
Installing Wheel Stud Into Hub And Bearing
1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on
wheel stud, then install a wheel lug nut on stud with flat
side of lug nut against washers.
2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing
assembly. When the head of the stud is fully seated against
the bearing flange, remove lug nut and washers from wheel stud.
3. Install the braking disk back on the hub and bearing assembly. 4. Install front brake caliper back
over braking disc and align with caliper mounting holes on steering knuckle. Install the caliper
adapter to steering
knuckle attaching bolts and torque to 19 Nm (168 inch. lbs.).
5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specification.
Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).
6. Lower vehicle to the ground.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1352
Wheel Fastener: Service and Repair Rear
REMOVAL
CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the
studs cannot be hammered out of the hub flange. If a stud is removed by hammering it out of the
bearing flange, damage to the hub and bearing assembly will occur leading to premature hub and
bearing failure.
The following procedure and special tools shown MUST be used when replacing wheel attaching
studs. The hub and bearing assembly does not require removal from the rear axle for replacement
of the wheel attaching studs. 1. Raise vehicle on jackstands or centered on a frame contact type
hoist. 2. Remove the rear wheel and tire assembly. 3. Remove the rear brake drum.
Removing Wheel Stud From Hub And Bearing
4. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly so the
threads on stud are even with end of lug nut. Install
Remover, Special Tool C-4150A on hub and bearing assembly flange and wheel stud.
5. Tightening down on special tool will push wheel stud out of the hub and bearing assembly
flange. Remove lug nut from stud and remove wheel
stud from flange.
INSTALLATION
Installing Wheel Stud Into Hub And Bearing
1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on
wheel stud, then install a wheel lug nut on stud with flat
side of lug nut against washers.
2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing
assembly. When the head of the stud is fully seated against
the bearing flange, remove lug nut and washers from wheel stud.
3. Install the rear brake drum on the hub and bearing assembly. 4. Install wheel and tire assembly
on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to
half specification.
Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).
5. Lower vehicle to the ground.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
Cylinder Compression Pressure:
Minimum 100 psi with no more than 25% variance between cylinders.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1358
Compression Check: Testing and Inspection
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions.
Ensure the battery is completely charged and the engine starter motor is in good operating
condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traffic and other forms of congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators: fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For Direct
Ignition System, disconnect the coil connector.
5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage. Record
this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than
(689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended compression pressures are to be used only as a guide
to diagnosing engine problems. An engine should not be disassembled to determine the cause of
low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test
resistance of spark plug cables. Refer to Powertrain Management. 13. Test coil output voltage,
primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at
idle and different RPM ranges.
Refer to Powertrain Management for Specifications.
15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation
system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Bearing > Component Information > Technical Service Bulletins > Engine - Camshaft/Bearing Inspection/Service
Camshaft Bearing: Technical Service Bulletins Engine - Camshaft/Bearing Inspection/Service
NUMBER: 09-007-02
GROUP: Engine
DATE: Oct. 21, 2002
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-008-01 DATED
NOVEMBER 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS.
SUBJECT: Camshaft/Bearing Service
MODELS: 1993 - **1997** (LH) Intrepid/Concorde/Vision 1996 - 2000 (GS) Chrysler Voyager
(International Markets) 1996 - 2000 (NS) Town & Country/Caravan/Voyager 2001 - **2003** (RG)
Chrysler Voyager (International Markets) 2001 - **2003** (RS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE (SALES
CODES EGA, EGB, EGH, EGM, EGP).
DISCUSSION: When it is necessary to replace a camshaft for any reason, the camshaft bearings
must be inspected for wear and/or damage. If wear or damage is present the short block must be
replaced. Excessive camshaft bearing wear could result in damage to the new replacement
camshaft. Camshaft bearings are only serviced with a short engine assembly.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Bearing > Component Information > Technical Service Bulletins > Page 1364
Camshaft Bearing: Specifications
DIAMETER:
No. 1
..............................................................................................................................................................
50.825 - 50.800 mm (2.0009 - 1.9999 inch) No. 2
..............................................................................................................................................................
50.419 - 50.393 mm (1.9849 - 1.9839 inch) No. 3
..............................................................................................................................................................
50.038 - 50.013 mm (1.9699 - 1.9690 inch) No. 4
..............................................................................................................................................................
49.632 - 49.606 mm (1.9540 - 1.9529 inch)
Oil Clearance
.........................................................................................................................................................
0.0254 - 0.0762 mm (0.001 - 0.003 inch)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Bearing > Component Information > Technical Service Bulletins > Page 1365
Camshaft Bearing: Service and Repair
REMOVAL
1. With engine removed from vehicle and completely disassembled, drive out rear cam bearing
core hole plug.
Removal/Installation Of Camshaft Bearings With Tool C-3132-A -Typical
2. Install proper size adapters and horseshoe washers (part of Tool C-3132-A) at back of each
bearing shell to be removed and drive out bearing
shells.
INSTALLATION
1. Install new camshaft bearings with Tool C-3132-A by sliding the new camshaft bearing shell over
proper adapter. 2. Position rear bearing in the tool. Install horseshoe lock and by reversing removal
procedure, carefully drive bearing shell into place. 3. Install remaining bearings in the same
manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages
from the
main bearing. Number two bearing must index with the oil passage to the left cylinder head and
Number three bearing must index with the oil passage to the right cylinder head. If the camshaft
bearing shell oil holes are not in exact alignment, remove and reinstall them correctly. Install a new
core hole plug at the rear of camshaft. Be sure this plug does not leak.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................
.................................................... 54 Nm (40 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Technical Service Bulletins > Engine - Camshaft/Bearing Inspection/Service
Camshaft: Technical Service Bulletins Engine - Camshaft/Bearing Inspection/Service
NUMBER: 09-007-02
GROUP: Engine
DATE: Oct. 21, 2002
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-008-01 DATED
NOVEMBER 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS.
SUBJECT: Camshaft/Bearing Service
MODELS: 1993 - **1997** (LH) Intrepid/Concorde/Vision 1996 - 2000 (GS) Chrysler Voyager
(International Markets) 1996 - 2000 (NS) Town & Country/Caravan/Voyager 2001 - **2003** (RG)
Chrysler Voyager (International Markets) 2001 - **2003** (RS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE (SALES
CODES EGA, EGB, EGH, EGM, EGP).
DISCUSSION: When it is necessary to replace a camshaft for any reason, the camshaft bearings
must be inspected for wear and/or damage. If wear or damage is present the short block must be
replaced. Excessive camshaft bearing wear could result in damage to the new replacement
camshaft. Camshaft bearings are only serviced with a short engine assembly.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Technical Service Bulletins > Page 1373
Camshaft: Specifications
Camshaft Drive Chain
Camshaft Bearings Steel Backed Babbit 4
Diametrical Clearance 0.001 - 0.004 in
Max Allowable 0.005 in
Thrust Taken By Thrust Plate
End Play 0.005 - 0.012 in
Max. Allowable 0.012 in
Camshaft Journals Bearing Journal Diameter No.1 1.997 - 1.999 in
Bearing Journal Diameter No.2 1.9809 - 1.9829 in
Bearing Journal Diameter No.3 1.9659 - 1.9679 in
Bearing Journal Diameter No.4 1.9499 -1.9520 in
Camshaft Bearings Diameter No.1 2.0009 - 1.999 in
Diameter No.2 1.9849 - 1.9839 in
Diameter No.3 1.9699 - 1.9690 in
Diameter No.4 1.954 - 1.9529 in
Oil Clearance 0.001 - 0.003 in
Valve Timing Exhaust Valve Closes (ATC) 12 deg
Opens (BBC) 48 deg
Duration 240 deg
Valve Timing Intake Valve Closes (BTDC) 58 deg
Opens 2 deg
Duration 240 deg
Valve Overlap 14 deg
Camshaft Thrust Plate Bolt 105 in.lb
Valves-Intake Lift (Zero Lash) 0.400 in
Valves-Exhaust Lift (Zero Lash) 0.40 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Technical Service Bulletins > Page 1374
Camshaft: Service and Repair
REMOVAL
1. Remove engine from vehicle.
Remove intake manifold, cylinder head covers, cylinder heads, timing chain case cover, and timing
chain.
2. Remove hydraulic tappets; identify so each part will be replaced in its original location.
Camshaft Thrust Plate
3. Remove camshaft thrust plate. 4. Install a long bolt into front of camshaft to facilitate removal of
the camshaft; remove camshaft, being careful not to damage cam bearings with the
cam lobes.
INSTALLATION
1. Lubricate camshaft lobes and camshaft bearing journals. 2. Insert the camshaft to within 2
inches of its final position in cylinder block. 3. Install camshaft thrust plate with two screws. Tighten
to 12 Nm (105 inch lbs.) torque. 4. Rotate crankshaft so the timing arrow is at the 12 o'clock
position. 5. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock
position. 6. Align the dark colored links with the dot on the camshaft sprocket, place timing chain
around crankshaft sprocket with the dark colored link lined
up with the dot on the sprocket and install camshaft sprocket into position.
Alignment Of Timing Marks
7. Use a straight edge to check alignment of timing marks. 8. Install the camshaft bolt. Tighten bolt
to 54 Nm (40 ft. lbs.). 9. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing
marks do not line up, remove cam sprocket and realign.
10. Measure camshaft end play. End Play should measure 0.0127 to 0.304 mm (0.005 to 0.012
inches.) 0.310 mm (0.012 in. Maximum). If not
within limits install a new thrust plate.
NOTE: When camshaft is replaced, all of the tappets must be replaced.
11. Install hydraulic tappets. Each tappet reused must be installed in the same position from which
it was removed. 12. Install timing chain, timing chain cover, cylinder heads, cylinder head covers,
and intake manifold. 13. Install engine assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications
Lifter / Lash Adjuster: Specifications
Hydraulic Tappets Roller Hydraulic
Body Diameter 0.9035 - 0.9040 in
Clearance in Block 0.0007 - 0.0024 in
Service Tappets Available 0.001,0.008, 0.030 in
Tappet Retainer Yoke Bolt 105 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications > Page 1378
Lifter / Lash Adjuster: Testing and Inspection
Roller Tappets Aligning Yoke And Retainer
The valve train includes roller tappet assemblies, aligning yokes and yoke retainer. Roller tappet
alignment is maintained by machined flats on tappet body being fitted in pairs into six aligning
yokes. The yokes are secured by an alignment yoke retainer.
PRELIMINARY STEP TO CHECKING THE HYDRAULIC TAPPETS
Before disassembling any part of the engine to correct tappet noise, read the oil pressure at the
gauge. Install a reliable gauge at pressure sending unit if vehicle has no oil pressure gauge and
check the oil level in the oil pan. The pressure should be between 30 and 80 psi (206.8 to 551.6
kPa) at 2000 rpm.
The oil level in the pan should never be above the MAX mark on dipstick, or below the MIN mark.
Either of these two conditions could be responsible for noisy tappets. Oil Level Check: stop engine
after reaching normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick.
OIL LEVEL TOO HIGH
If oil level is above the MAX mark on dip stick, it is possible for the connecting rods to dip into the
oil while engine is running and create foam. Foam in oil pan would be fed to the hydraulic tappets
by the oil pump causing them to become soft and allow valves to seat noisily.
OIL LEVEL TOO LOW
Low oil level may allow pump to take in air which when fed to the tappets, causes them to become
soft and allows valves to seat noisily. Any leaks on intake side of pump through which air can be
drawn will create the same tappet action. Check the lubrication system from the intake strainer to
the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may
be intermittent or constant, and usually more than one tappet will be noisy. When oil level and
leaks have been corrected, engine should be operated at fast idle to allow all of the air inside of the
tappets to be bled out.
VALVE TRAIN NOISE DIAGNOSIS
To determine source of valve train noise, operate engine at idle with cylinder head covers removed
and listen for source of the noise.
NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side thrust on the valve spring. If noise is not
appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod
sockets and push rod ends for wear.
Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by
excessive leak-down around the unit plunger which will necessitate replacing the tappet, or by the
plunger partially sticking in the tappet body cylinder. A heavy click is caused either by a tappet
check valve not seating, or by foreign particles becoming wedged between the plunger and the
tappet body causing the plunger to stick in the down position. This heavy click will be accompanied
by excessive clearance between the valve stem and rocker arm as valve closes. In either case,
tappet assembly should be removed for inspection and cleaning.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Removal and Installation
Lifter / Lash Adjuster: Service and Repair Removal and Installation
REMOVAL Cylinder head must be removed to gain access to hydraulic tappets for service.
1. Remove cylinder head. 2. Remove yoke retainer and aligning yokes. 3. Use Special Tool
C-4129, or equivalent to remove tappets from their bores. If all tappets are to be reused, identify
tappets to insure installation in
original location.
NOTE: If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the
bore to next oversize and replace with oversize tappet.
CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing
of parts. Mixed parts are not compatible. Do not disassemble a tappet on a dirty work bench.
INSTALLATION
1. Lubricate tappets. 2. Install hydraulic tappets. Install tappets in their original positions, if reused.
Roller Tappets Aligning Yoke And Retainer
3. Install tappet aligning yokes. 4. Install yoke retainer and torque screws to 12 Nm (105 inch lbs.).
5. Install cylinder heads. 6. Start and operate engine. Warm up to normal operating temperature.
CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have become quiet.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Removal and Installation > Page 1381
Lifter / Lash Adjuster: Service and Repair Disassembly and Assembly
DISASSEMBLY
Hydraulic Roller Tappet Assembly
1. Pry out plunger retainer spring clip. 2. Clean varnish deposits from inside of tappet body above
plunger cap. 3. Invert tappet body and remove plunger cap, plunger, flat or ball check valve, check
valve spring, check valve retainer and plunger spring. Check
valve could be flat or ball.
ASSEMBLY
1. Clean all tappet parts in a solvent that will remove all varnish and carbon. 2. Replace tappets
that are unfit for further service with new assemblies. 3. If plunger shows signs of scoring or wear,
valve is pitted, or valve seat on end of plunger indicates any condition that would prevent valve
from
seating, install a new tappet assembly.
4. Assemble tappets.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Shaft Bracket Bolts 250 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1385
Rocker Arm Assembly: Service and Repair
ROCKER ARMS AND SHAFT ASSEMBLY
REMOVAL 1. Remove upper intake manifold assembly. 2. Disconnect spark plug wires by pulling
on the boot straight out in line with plug. 3. Disconnect closed ventilation system. 4. Remove
cylinder head cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6. Remove rocker
arms and shaft assembly.
Rocker Arm Location Left Bank
7. If rocker arm assemblies are disassembled for cleaning or replacement, assemble rocker arms
in their original position.
INSTALLATION 1. Install rocker arm and shaft assemblies with the stamped steel retainers in the
four positions, tighten to 28 Nm (250 inch lbs.).
CAUTION: THE ROCKER ARM SHAFT SHOULD BE TORQUED DOWN SLOWLY, STARTING
WITH THE CENTER BOLTS. ALLOW 20 MINUTES TAPPET BLEED DOWN TIME AFTER
INSTALLATION OF THE ROCKER SHAFTS BEFORE ENGINE OPERATION.
2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten, if
necessary. 3. Clean cylinder head sealing surfaces. Install a new gasket and tighten cylinder head
cover fasteners to 12 Nm (105 inch lbs.). 4. Install closed crankcase ventilation system. 5. Install
spark plug wires. 6. Install upper intake manifold assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Specifications
Connecting Rod Bearing: Specifications
Bearing Clearance
........................................................................................................................................... 0.019 0.065 mm (0.00075 - 0.0026 inch)
Wear Limit ...........................................................................................................................................
............................................ 0.76 mm (0.003 inch)
Side Clearance
.......................................................................................................................................................
0.127 - 0.381 mm (0.005 - 0.015 inch)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Connecting Rod Cap Bolts/Nuts
Connecting Rod: Specifications Connecting Rod Cap Bolts/Nuts
TORQUE SPECIFICATIONS
Connecting Rod Cap Nuts
.............................................................................................................................................. 54 Nm
(40 ft. lbs.) Plus 1/4 turn
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1394
Connecting Rod: Specifications Connecting Rod Specifications
Connecting Rod
Bearing Type .......................................................................................................................................
..................................... Aluminum Lead (Bimetal) Bearing Clearance
...............................................................................................................................................
0.019-0.065 mm (0.00075-0.0026 inch) Max. Allowable .....................................................................
........................................................................................................ 0.076 mm (0.003 inch) Side
Clearance
...........................................................................................................................................................
0.127-0.381 mm (0.005-0.015 inch)
Connecting Rod Journals
Diameter
............................................................................................................................................................
58.005-57.979 mm (2.2837-2.2827 inch) Out-of-Round (Max.) ..........................................................
........................................................................................................... 0.025 mm (0.001 inch) Taper
(Max.) ..................................................................................................................................................
................................ 0.025 mm (0.001 inch)
TORQUE SPECIFICATIONS
Rod Nut ...............................................................................................................................................
............................ 54 Nm (40 ft. lbs.) plus 1/4 turn
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Page 1395
Connecting Rod: Service and Repair
Fit all rods on one bank until complete.
The bearing caps are not interchangeable and should be marked at removal to insure correct
assembly.
The bearing shells must be installed with the tangs inserted into the machined grooves in the rods
and caps. Install cap with the tangs on the same side as the rod.
Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch).
Bearings are available in 0.025 mm (0.001 inch) and 0.250 mm (0.010 inch) undersize. Install the
bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or
bearing caps.
Checking Connecting Rod Bearing Clearance
1. Follow procedure specified in the Standard Service Information, Measuring With Plastigage,
found under Engine, Service and Repair for
Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance. See: Service and
Repair/Standard Procedures/Measuring With Plastigage
Check For Stretched (Necked) Bolts
NOTE: The rod bearing bolts should be examined before reuse. If the threads are necked down the
bolts should be replaced. Necking can be checked by holding a scale or straight edge against the
threads. If all the threads do not contact the scale the bolt should be replaced.
2. Before installing the nuts the threads should be oiled with engine oil. 3. Install nuts finger tight on
each bolt then alternately torque each nut to assemble the cap properly. 4. Tighten the nuts to 54
Nm PLUS 1/4 turn (40 ft. lbs. PLUS 1/4 turn).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Page 1396
Checking Connecting Rod Side Clearance
5. Using a feeler gauge, check connecting rod side clearance. Refer to Connecting Rod
Specification Chart.
Connecting Rod Specification Chart
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Specifications
Crankshaft Main Bearing: Specifications
Crankshaft Cast Nodular Iron
Thrust Location No. 2 Bearing
Connecting Rod Journal Diameter 2.124 - 2.125 in
Main Bearing Diametrical Clearance No.1-4 0.0043 - 0.0023 in
Max. Allowable 0.004 in
End Play 0.0036 - 0.0095 in
Max. Allowable 0.015 in
Main Bearing Journals Diameter 2.5202 - 2.5195 in
Out-of-Round 0.001 in
Taper (Max.) 0.001 in
Connecting Rod Journals Diameter 2.2837 - 2.2827 in
Out-of-Round 0.001 in
Taper (Max.) 0.001 in
Main Bearing Cap Bolts 30 ft.lb
plus 1/4 turn
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Crankshaft Cast Nodular Iron
Thrust Location No. 2 Bearing
Connecting Rod Journal Diameter 2.124 - 2.125 in
Main Bearing Diametrical Clearance No.1-4 0.0043 - 0.0023 in
Max. Allowable 0.004 in
End Play 0.0036 - 0.0095 in
Max. Allowable 0.015 in
Main Bearing Journals Diameter 2.5202 - 2.5195 in
Out-of-Round 0.001 in
Taper (Max.) 0.001 in
Connecting Rod Journals Diameter 2.2837 - 2.2827 in
Out-of-Round 0.001 in
Taper (Max.) 0.001 in
Main Bearing Cap Bolts 30 ft.lb
plus 1/4 turn
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Removal and Installation
Crankshaft: Service and Repair Removal and Installation
MAIN BEARINGS
Main Bearing Cap Identification
Bearing caps are not interchangeable and should be marked at removal to insure correct
assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves
of 1, 3, and 4 are interchangeable. Upper main bearing halves of 1, 3, and 4 are interchangeable.
CRANKSHAFT MAIN JOURNALS
Measuring Crankshaft Journal O.D.
The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Journal grinding
should not exceed 0.305 min (0.012 inch) under the standard journal diameter. Do NOT grind
thrust faces of Number 2 main bearing. Do NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth
polish after any journal regrind be in the same direction as normal rotation in the engine.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1405
Main Bearing Identification
Upper and lower number 2 bearing halves are flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves in the engine. All bearing cap bolts removed
during service procedures are to be cleaned and oiled before installation. Bearing shells are
available in standard and the following undersizes: 0.025 min (0.001 inch) and 0.254 mm (0.010
inch). Never install an undersize bearing that will reduce clearance below specifications.
REMOVAL
1. Remove oil pan and identify bearing caps before removal.
Removing And Installing Upper Main Bearing With Special Tool C-3059
2. Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main
Bearing Tool C-3059 into the oil hole of crankshaft. 3. Slowly rotate crankshaft clockwise, forcing
out upper half of bearing shell.
INSTALLATION
NOTE: Only one main bearing should be selectively fitted while all other main bearing caps are
properly tightened.
When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. 1.
Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft. 2. Slowly
rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing
Tool C-3059. 3. Install each main cap and tighten bolts finger tight. 4. Tighten number 1, 3 and 4
main cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). 5. Rotate the crankshaft until number 6
piston is at TDC. 6. To ensure correct thrust bearing alignment the following procedure must be
done:
a. Move crankshaft all the way to the rear of its travel. b. Then, move crankshaft all the way to the
front of its travel. c. Wedge a appropriate tool between the rear of the cylinder block and rear
crankshaft counterweight. This will hold the crankshaft in its most
forward position.
d. Tighten the #2 Thrust Bearing cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the
holding tool.
7. Install oil pan. 8. Fill engine crankcase with proper oil to correct level.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1406
Crankshaft: Service and Repair Service Procedures
Crankshaft End Play Measurement
DIAL INDICATOR METHOD
Checking Crankshaft End Play
1. Mount a dial indicator to front of engine, locating probe on nose of crankshaft. 2. Move
crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the
way to the front and read the dial indicator. Refer to Crankshaft Specification Chart.
FEELER GAUGE METHOD
1. Move crankshaft all the way to the rear of its travel using a lever inserted between a main
bearing cap and a crankshaft cheek using care not to
damage any bearing surface. Do not loosen main bearing cap.
2. Use a feeler gauge between number 2 thrust bearing and machined crankshaft surface to
determine end play. Refer to Crankshaft Specification
Chart.
Crankshaft Specification Chart
Fitting Bearings
CRANKSHAFT OIL CLEARANCE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1407
Measure Crankshaft Journal O.D.
Measure the journal outside diameter. Refer to Crankshaft Specification Chart.
Crankshaft Specification Chart
CRANKSHAFT SPECIFICATION CHART
PLASTIGAGE (OIL CLEARANCE) MEASUREMENT
1. Remove oil from journal and bearing shell. 2. Install crankshaft.
Measuring Beaing Clearance With Plastigage
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1408
3. Cut plastigage to same length as width of the bearing and place it in parallel with the journal
axis. 4. Install the main bearing cap carefully and tighten the bolts to specified torque.
CAUTION: Do not rotate crankshaft or the Plastigage will be smeared.
5. Carefully remove the bearing cap and measure the width of the plastigage at the widest part
using the scale on the plastigage package. Refer to
Crankshaft Specification Chart for proper clearances. If the clearance exceeds the specified limits,
replace the main bearing(s) and if necessary, have the crankshaft machined to next undersize.
CAUTION: Do not rotate crankshaft or the Plastigage may be smeared.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Description and Operation
Engine Block Heater: Description and Operation
The engine block heater is available as an optional accessory on all models. The heater is
operated by ordinary house current (110 Volt A.C.) through a power cord located behind the
radiator grille. This provides easier engine starting and faster warm-up when vehicle is operated in
areas having extremely low temperatures. The heater is mounted in a core hole (in place of a core
hole plug) in the engine block, with the heating element immersed in coolant.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Description and Operation > Page 1412
Engine Block Heater: Service and Repair
REMOVAL
1. Drain coolant from radiator and cylinder block. 2. Remove power cord plug from heater. 3.
Loosen screw in center of heater. Remove heater assembly.
INSTALLATION
1. Thoroughly clean core hole and heater seat. 2. Insert heater assembly with element loop
positioned upward. 3. With heater seated, tighten center screw securely to assure a positive seal.
4. Fill cooling system with coolant to the proper level, vent air, and inspect for leaks. Pressurize
system with Radiator Pressure Tool before looking
for leaks.
5. Install power cord plug to heater.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug >
Component Information > Service and Repair
Expansion/Freeze Plug: Service and Repair
REMOVAL
Core Hole Plug Removal
Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the
cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug.
CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopar(R) Stud N' Bearing Mount or equivalent. Make
certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into oil
gallery hole so that the sharp edge of the plug is at least 0.5 mm (0.020 inch) inside the lead-in
chamfer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley
Harmonic Balancer - Crankshaft Pulley: Specifications Chrankshaft Pulley
Chrankshaft Pulley
Torque Specifications 54 Nm (40 ft.lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley > Page 1420
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Damper Pulley to Crankshaft Bolt 40 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1421
Harmonic Balancer - Crankshaft Pulley: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. 3. Remove right wheel and
inner splash shield. 4. Remove drive belt.
Crankshaft Damper-Removal
5. Remove crankshaft pulley.
INSTALLATION
Crankshaft Damper-Installation
1. Install crankshaft pulley using plate L-4524, thrust bearing/washer and C-4685-Cl, 5.9 inch
screw. 2. Install drive belt. 3. Install inner splash shield and wheel. 4. Connect negative cable to
battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Pistons Aluminum Alloy Tin Coated
Clearance at Size Location 0.001 - 0.0022 in
Weight (Standard Only)-3.3L 13.4394 +/-0.1764
Weight (Standard Only)-3.8L 15.4501 +/-0.1764
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation
Piston: Service and Repair Removal and Installation
REMOVAL
1. Disconnect negative cable from battery. 2. Remove cylinder heads and oil pan. 3. Remove top
ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be
sure to keep tops of pistons
covered during this operation. Pistons and connecting rods must be removed from top of cylinder
block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so
that each connecting rod is centered in cylinder bore.
Identify Connecting Rod To Cylinder
4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them, if
necessary.
Connecting Rod Protectors
5. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push
each piston and rod assembly out of cylinder
bore.
NOTE: Be careful not to nick crankshaft journals.
6. After removal, install bearing cap on the mating rod.
INSTALLING PISTON AND CONNECTING ROD ASSEMBLY
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1427
Piston Ring End Gap Position
1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line
with oil ring rail gap.
2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the
rail gaps. 3. Lubricate the piston and rings with clean engine oil. Position a ring compressor over
the piston and rings, and tighten the compressor. Be sure
position of rings does not change during this operation.
4. Install connecting rod bolt protectors on rod bolts.
Piston-Installation
5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod
over the crankshaft journal.
6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide
connecting rod into position on connecting rod journal.
Piston I.D. Notches
7. The notch or groove on top of piston must be pointing toward front of engine. 8. Install rod caps.
Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nm (40 ft. lbs.) Plus 1/4 turn. 9.
Repeat procedure for each piston and rod installation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1428
10. Install cylinder heads and oil pan. 11. Fill engine crankcase with proper oil to correct level. 12.
Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1429
Piston: Service and Repair Fitting Pistons and Rings
FITTING PISTONS
Piston Measurements
Checking Cylinder Bore Size
The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90
degrees to piston pin at size location. Cylinder bores should be measured halfway down the
cylinder bore and transverse to the engine crankshaft center line. Refer to Cylinder Bore and Piston
Specification Chart. Pistons and cylinder bores should be measured at normal room temperature,
70°F (21°).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1430
CYLINDER BORE AND PISTON SPECIFICATION CHART
Check Gap On Piston Rings
FITTING RINGS
1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore.
The ring gap measurement must be made with the
ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler
gauge. Refer to Piston Ring Specification Chart.
Measuring Piston Ring Side Clearance
2. Check piston ring to groove clearance. Refer to Piston Ring Specification Chart.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1431
Piston Ring Specification Chart
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Pistons Pins Press Fit in Rods (Serrviced as an Assembly)
Diameter 0.9009 - 0.9007 in
Length-3.3L 2.648 - 2.667 in
Length-3.8L 2.805 - 2.824 in
Clearance in Piston @70' 0.0002 - 0.0007 in
Clearance in Rod (Interference)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Number of Rings 3
Compression 2
Oil Control 1
Oil Ring Type 3-Piece, Steel Rail, Chrome Face
Piston Ging Gap Top and 2nd Compression Ring 0.0118 - 0.0217 in
Oil Control (Steel Rails) 0.0098 - 0.0394 in
Service Rings Ring Gap-Compression 0.0188 - 0.0217 in
Ring Gap-Oil Control 0.0098 - 0.0394 in
Piston Ring Side Clearance Top and 2nd Compression Rings 0.0012 - 0.0037 in
Oil Rings (Steel Rails) 0.0005 - 0.0089 in
Piston Ring Width Compression Rings 0.0575 - 0.0591 in
Oil Ring (Steel Rails) 0.0201 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and
therefore does not require adjustment.
See "Rocker Arm: Service and Repair" for further information.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions > Page 1445
Fuel Pressure Release: Service and Repair
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap.
Fuel Pressure Test Port
Releasing Fuel Pressure
3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel
pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other
end of hose C-4799-1 to
fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container.
Fuel gauge C-4799-B contains hose C-4799-1.
5. Replace Pressure test port cap when finished doing pressure test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Shaft Bracket Bolts 250 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 1449
Rocker Arm Assembly: Service and Repair
ROCKER ARMS AND SHAFT ASSEMBLY
REMOVAL 1. Remove upper intake manifold assembly. 2. Disconnect spark plug wires by pulling
on the boot straight out in line with plug. 3. Disconnect closed ventilation system. 4. Remove
cylinder head cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6. Remove rocker
arms and shaft assembly.
Rocker Arm Location Left Bank
7. If rocker arm assemblies are disassembled for cleaning or replacement, assemble rocker arms
in their original position.
INSTALLATION 1. Install rocker arm and shaft assemblies with the stamped steel retainers in the
four positions, tighten to 28 Nm (250 inch lbs.).
CAUTION: THE ROCKER ARM SHAFT SHOULD BE TORQUED DOWN SLOWLY, STARTING
WITH THE CENTER BOLTS. ALLOW 20 MINUTES TAPPET BLEED DOWN TIME AFTER
INSTALLATION OF THE ROCKER SHAFTS BEFORE ENGINE OPERATION.
2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten, if
necessary. 3. Clean cylinder head sealing surfaces. Install a new gasket and tighten cylinder head
cover fasteners to 12 Nm (105 inch lbs.). 4. Install closed crankcase ventilation system. 5. Install
spark plug wires. 6. Install upper intake manifold assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Specifications
Valve Cover: Specifications
Cylinder Head Cover Bolts 105 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Specifications > Page 1453
Valve Cover: Service and Repair
REMOVAL
Cylinder Head Cover-Isolated Type
NOTE: The cylinder head cover can be either an isolated type or a non-isolated type.
FRONT CYLINDER HEAD COVER 1. Disconnect ignition cables from spark plugs. 2. Disconnect
crankcase vent hose from cylinder head cover. 3. Remove front cylinder head cover bolts. 4.
Remove cylinder head cover and gasket.
REAR CYLINDER HEAD COVER 1. Disconnect negative cable from battery. 2. Remove wiper unit.
3. Remove intake manifold upper plenum. 4. Disconnect PCV hose from cylinder head cover. 5.
Remove rear cylinder head cover bolts 6. Remove cylinder head cover and gasket.
INSTALLATION
FRONT CYLINDER HEAD COVER 1. Clean cylinder head and cover mating surfaces. Inspect
cylinder head cover surface for flatness. Replace gasket as necessary. 2. Install cylinder head
cover and bolts. 3. Tighten cylinder head cover bolts to the following specifications:
- Non-isolated cylinder head cover to 12 Nm (105 inch lbs.).
- Isolated cylinder head cover to 10 Nm (90 inch lbs.).
4. Connect crankcase vent hose. 5. Connect ignition cables to spark plugs.
REAR CYLINDER HEAD COVER 1. Clean cylinder head and cover mating surfaces. Inspect
cylinder head cover surface for flatness. Replace gasket as necessary. 2. Install cylinder head
cover and bolts. 3. Tighten cylinder head cover bolts to the following specifications:
^ Non-isolated cylinder head cover to 12 Nm (105 inch lbs.).
^ Isolated cylinder head cover to 10 Nm (90 inch lbs.).
4. Connect PCV hose from cylinder head cover. 5. Install intake manifold upper plenum. 6. Install
wiper unit. 7. Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Specifications > Dimensions
Valve Guide: Specifications
Overall Length-Intake 1.732 in
Overall Length-Exhaust 1.889 in
Outside Diameter 0.514 - 0.5143 in
Inside Diameter 0.314 - 0.315 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Specifications > Dimensions > Page 1458
Valve Guide: Specifications Type
Guide Type Specifications
Guide Material .....................................................................................................................................
......................................... Powdered Metal Inserts
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Specifications > Page 1459
Valve Guide: Service and Repair
NOTE: Replace cylinder head if guide does not clean up with 0.80 mm (0.030 inch) oversize
reamer, or if guide is loose in cylinder head.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications
Valve Seat: Specifications
Angle-Intake and Exhaust 45 - 45.5 deg
Runout (Max.) 0.003 in
Width (Finish)-Intake 0.069 - 0.088 in
Width (Finish)-Exhaust 0.057 - 0.078 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications > Page 1463
Valve Seat: Service and Repair
Refer to Valve, Intake/Exhaust, Service and Repair, Valve Service/Recondition for procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Specifications
Valve Spring: Specifications
Free Length (Approx.) 1.909 in
Wire Diameter 0.187 in
Number of Coils 6.8
Spring Tension (Valve Closed) 95 - 100 lbf at 1.57 in
Spring Tension (Valve Open) 207 - 229 lbf at 1.169 in
Installed Height (Spring Seat to Bottom of Retainer) 1.622 - 1.681 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service and Repair > Cylinder Head Off
Valve Spring: Service and Repair Cylinder Head Off
Refer to Valve, Intake/Exhaust, Service and Repair for procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service and Repair > Cylinder Head Off > Page 1469
Valve Spring: Service and Repair Cylinder Head On
1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect
negative cable from battery 3. Remove air cleaner cover and hose assembly. 4. Remove upper
intake manifold. 5. Remove cylinder head covers and spark plugs. 6. Remove electrical connector
from ignition coils. 7. Using suitable socket and flex handle at crankshaft pulley retaining screw,
turn engine so the number 1 piston is at TDC on the compression
stroke.
8. Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be
disturbed and left on shaft. 9. With air hose attached to spark plug adapter installed in number 1
spark plug hole, apply 90 to 100 psi air pressure (620.5 to 689 kPa). This is to
hold valves in place while servicing components.
10. Using Tool C-4682 or equivalent, compress valve spring and remove retainer valve locks and
valve spring. 11. The intake valve stem seals should be pushed firmly and squarely over the valve
guide using the valve stem as guide. Do not force seal against top
of guide. When installing the valve retainer locks, compress the spring only enough to install the
locks.
CAUTION: Do not pinch seal between retainer and top of valve guide.
12. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6.
Make sure piston in cylinder is at TDC on the valve
spring that is being covered.
13. Remove spark plug adapter tool. 14. Remove dummy shaft and install rocker shaft assembly
and tighten screws to 28 Nm (250 inch lbs.). 15. Install cylinder head covers tighten screws to 14
Nm (120 inch lbs.) and electrical connector to ignition coils. 16. Install intake manifold. 17. Connect
negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service and Repair > Cylinder Head Off > Page 1470
Valve Spring: Service and Repair Inspection
Refer to Valve, Intake/Exhaust, Service and Repair for procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications
Valve: Specifications
Valves-Intake Face Angle 44.5 deg
Head Diameter 1.79 in
Lenght (Overall) 5.000 - 5.041 in
Minimum Valve Length After Tip Grinding 4.916 in
Stem Diameter (Standard) 0.312 - 0.313 in
Valve Tip Height (From Cylinder Head Surface) 1.950 - 2.018 in
Stem-to-Guide Clearance 0.001 - 0.003 in
Max. Allowable (Rocking Method) 0.010 in
Valves for Service (Oversize Stem Diameters) 0.005, 0.015, 0.030 in
Valves-Exhaust Face Angle 45 deg
Head Diameter 1.476 in
Legth Overall 5.032 - 5.058 in
Minimum Valve Length After Grinding 4.941 in
Valve Tip Height (From Cylinder Head Surface) 1.950 - 2.018 in
Stem Diameter (Strandard) 0.3112 - 0.3119 in
Stem to Guide Clearance 0.002 - 0.006 in
Max. Allowable (Rocking Method) 0.016 in
Valves for Service (Oversize Stem Diameters 0.005, 0.015, 0.030 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation
Valve: Service and Repair Removal and Installation
REMOVAL
Compress Valve Springs With Special Tool C-3422-B With Adapter 6412
1. With cylinder head removed, compress valve springs using Valve Spring Compressor Tool
C-3422-B with adapter 6412. 2. Remove valve retaining locks, valve spring retainers, valve stem
seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock
grooves to prevent damage to the valve guides. Identify valves to insure
installation in original location.
VALVE INSTALLATION
1. Coat valve stems with clean engine oil and insert them in cylinder head.
Checking Valve Installed Height
2. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve
tip to give 49.541 to 51.271 mm (1.950 to 2.018
inch) over spring seat when installed in the head. Check valve tip for scoring, if necessary, the tip
chamfer should be reground to prevent seal damage when the valve is installed.
Valve Seal And Spring-Installation
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1476
3. Install valve spring seat spacer on head. 4. Install new cup seals on all valve stems and over
valve guides. Install valve springs and valve retainers. 5. Compress valve springs with Valve Spring
Compressor Tool C-3422-13, with adapter 6412 install locks and release tool. If valves and/or
seats are
reground, measure the installed height of springs dimension B, make sure measurements are
taken from top of spring seat to the bottom surface of spring retainer. If height is greater than
1-19/32 inches, (40.6 mm), install a 1/32 inch (0.794 mm) spacer in head counterbore to bring
spring height back to normal 1-17/32 to 1-19/32 inch (39.1 to 40.6 mm).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1477
Valve: Service and Repair Valve Service
Intake And Exhaust Valves
VALVE INSPECTION
1. Clean valves thoroughly and discard burned, warped and cracked valves. 2. Measure valve
stems for wear. Refer to Valve Specification.
CAUTION: Valve stems are chrome plated and should not be polished.
3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 4.
Measure valve stem guide clearance as follows:
a. Install valve into cylinder head so it is 14 mm (0.551 inch) off the valve seat. A small piece of
hose may be used to hold valve in place.
Measuring Valve Guide Wear
b. Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being
measured.
5. Move valve to and from the indicator. Refer to Valve Guide Specification Chart.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1478
VALVE GUIDE SPECIFICATION CHART
6. Ream the guides for valves with oversized stems if dial indicator reading is excessive or if the
stems are scuffed or scored. 7. Service valves with oversize stems and over size seals are
available in 0.15 mm (0.005 inch), 0.40 mm, (0.015 inch) and 0.80 mm (0.030 inch)
oversize.
NOTE: Oversize seals must be used with oversize valves.
8. Refer to Valve Guide Specification Chart for reamer size to accommodate the oversize valve
stems. 9. Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Do
not attempt to ream the valve guides from standard
directly to 0.80 mm (0.030 inch). Use step procedure of 0.15 mm (0.005 inch), 0.40 mm (0.015
inch) and 0.80 mm (0.030 inch) so the valve guides may be reamed true in relation to the valve
seat. After reaming guides, the seat runout should be measured and resurfaced if necessary. See
Refacing Valves and Valve Seats.
VALVE GUIDES
NOTE: Replace cylinder head if guide does not clean up with 0.80 mm (0.030 inch) oversize
reamer, or if guide is loose in cylinder head.
REFACING VALVES AND VALVE SEATS
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1479
Valve Seats
The intake and exhaust valves have a 44-1/2 to 45 degree face angle. The valve seats have a 45
to 45-1/2 degree face angle. The valve face and valve seat angles are shown in the image..
VALVES 1. Inspect the remaining margin after the valves are refaced. Refer to Valve Specification
Chart.
VALVE SPECIFICATION CHART
VALVE SEATS
Refacing Valve Seats
CAUTION: Remove metal from valve seat only. Do not remove metal from cylinder head.
1. When refacing valve seats, it is important that the correct size valve guide pilot be used for
reseating stones. A true and complete surface must be
obtained.
2. Measure the concentricity of valve seat using dial indicator. Total runout should not exceed
0.051 mm (0.002 inch) total indicator reading.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1480
3. Inspect the valve seat using Prussian blue to determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center
of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, lower valve
seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face raise valve
seat with a 65 degree stone.
NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and
seat width are maintained. Otherwise cylinder head must be replaced.
Valve Seats
4. When seat is properly positioned, the width of intake seats should be 1.75 to 2.25 mm (0.69 to
0.088 inch). The width of the exhaust seats should
be 1.50 to 2.00 mm (0.059 to 0.078 inch).
Checking Valve Installed Height (Part 1 Of 2)
Checking Valve Installed Height (Part 2 Of 2)
5. Check the valve spring installed height after refacing the valve and seat.
TESTING VALVE SPRINGS
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1481
Testing Valve Springs
Whenever valves have been removed for inspection, reconditioning or replacement, valve springs
should be tested. As an example, the compression length of the spring to be tested is 33.34 mm
(1-5/16 inches). Turn table of Tool C-647 until surface is in line with the 33.34 mm (1-5/16 inch)
mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and
lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on
torque wrench at this instant. Multiply this reading by two. This will give the spring load at test
length. Fractional measurements are indicated on the table for finer adjustments. Refer to
specifications to obtain specified height and allowable tensions. Discard the springs that do not
meet specifications.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99
> A/C Compressor - Locks Up At Low Mileage
Drive Belt: Customer Interest A/C Compressor - Locks Up At Low Mileage
Number: 24-15-99
Group: Heating & A/C
Date: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED
AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE
1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Compressor Lock-Up At Low Mileage
OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either
working the compressor loose or replacing it.
MODELS:
1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager
(International Market) 1998 - **2000** (PL) Neon
NOTE:
THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH
AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE
OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE
ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR.
SYMPTOM/CONDITION:
The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing
a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN
THE COMPRESSOR HAS FAILED.
With the close internal clearances of a compressor operating in an R134A system, it is possible to
experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system
is inactive, the more likely the lock-up condition is to occur.
This condition is the result of normal refrigerant movement within the A/C system caused by
temperature differences between the various components (evaporator, condenser, compressor)
that "washes" the oil out of the compressor.
DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt
to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the
A/C system is turned off perform the Repair Procedure.
REPAIR PROCEDURE:
This bulletin involves determining the extent of A/C compressor lock-up and either working the
compressor loose or replacing it.
Before assuming the A/C compressor has failed and must be replaced, the following steps should
be taken.
1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the
A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate
the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate
the compressor is internally damaged and must be replaced, skip to step 7.
2. Turn the hub clockwise five complete revolutions and remove the tool.
3. Start the vehicle, turn on the A/C system, and run at idle.
4. Observe the A/C compressor and system for normal operation for both cool-down and noise
level standpoints.
5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and
testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system
to operate at idle for 5 minutes.
6. If acceptable performance continues throughout the five minutes, the compressor does not need
to be replaced, skip to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99
> A/C Compressor - Locks Up At Low Mileage > Page 1491
7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the
procedure outlined in the appropriate Service Manual to replace the A/C compressor.
8. Inspect the drive belt for damage, replace it if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs.
24-10-01-93 Replace Compressor 1.2 Hrs.
FAILURE CODE: 07 - Binds, Sticks or Seized
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist
Drive Belt: Customer Interest Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist > Page 1496
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist > Page 1497
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist > Page 1498
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage
Drive Belt: All Technical Service Bulletins A/C Compressor - Locks Up At Low Mileage
Number: 24-15-99
Group: Heating & A/C
Date: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED
AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE
1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Compressor Lock-Up At Low Mileage
OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either
working the compressor loose or replacing it.
MODELS:
1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager
(International Market) 1998 - **2000** (PL) Neon
NOTE:
THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH
AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE
OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE
ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR.
SYMPTOM/CONDITION:
The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing
a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN
THE COMPRESSOR HAS FAILED.
With the close internal clearances of a compressor operating in an R134A system, it is possible to
experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system
is inactive, the more likely the lock-up condition is to occur.
This condition is the result of normal refrigerant movement within the A/C system caused by
temperature differences between the various components (evaporator, condenser, compressor)
that "washes" the oil out of the compressor.
DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt
to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the
A/C system is turned off perform the Repair Procedure.
REPAIR PROCEDURE:
This bulletin involves determining the extent of A/C compressor lock-up and either working the
compressor loose or replacing it.
Before assuming the A/C compressor has failed and must be replaced, the following steps should
be taken.
1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the
A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate
the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate
the compressor is internally damaged and must be replaced, skip to step 7.
2. Turn the hub clockwise five complete revolutions and remove the tool.
3. Start the vehicle, turn on the A/C system, and run at idle.
4. Observe the A/C compressor and system for normal operation for both cool-down and noise
level standpoints.
5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and
testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system
to operate at idle for 5 minutes.
6. If acceptable performance continues throughout the five minutes, the compressor does not need
to be replaced, skip to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1504
7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the
procedure outlined in the appropriate Service Manual to replace the A/C compressor.
8. Inspect the drive belt for damage, replace it if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs.
24-10-01-93 Replace Compressor 1.2 Hrs.
FAILURE CODE: 07 - Binds, Sticks or Seized
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist
Drive Belt: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1509
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1510
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1511
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1512
Accessory Drive Belt-3.3/3.8L Engines
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1513
Drive Belt: Description and Operation
The accessory drive system utilizes two different style of drive belts. The conventional V-belt and
the Poly-V belt are used to drive the generator, air conditioning compressor, power steering pump
and water pump. Satisfactory performance of these belts depends on belt condition and proper belt
tension. Belt tensioning should be performed with the aid of a Belt Tension Gauge, Special Tool
7198. Because of space limitations in the engine compartment, the use of this gauge may be
restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the
drive belts, if necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1514
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1515
Drive Belt: Adjustments
Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt
tensioning should be performed with the aid of Special Tool 7198. Because of space limitations in
the engine compartment, the use of this gauge may be restricted. Raise the vehicle on a hoist and
the remove the splash shield to gain access to the drive belts, if necessary.
BELT TENSION GAUGE METHOD
Use belt tension gauge, Special Tool 7198.
Adjust belt tension for either a New or Used belt. For specifications, refer to Belt Tension Chart.
BELT TENSION CHART
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Removal and Installation
Drive Belt: Service and Repair Removal and Installation
A/C Belt
Refer to Drive Belt, Alternator for procedure.
Alternator Belt
Accessory Drive Belt-3.3/3.8L Engines
The Poly-V serpentine drive belt is provided with a dynamic tensioner to maintain proper belt
tension to drive the following components:
^ generator
^ power steering pump
^ air conditioning compressor
^ water pump
REMOVAL
1. Raise vehicle on hoist.
Accessory Drive Belt Splash Shield
2. Remove accessory drive belt splash shield.
WARNING: DO NOT ALLOW DRIVE BELT TENSIONER TO SNAP BACK, AS DAMAGE TO
TENSIONER AND/OR PERSONAL INJURY COULD RESULT.
3. Release belt tension by rotating the tensioner clockwise. 4. Remove drive belt.
INSTALLATION
1. Properly route and position belt onto all pulleys, except for the tensioner pulley. 2. Rotate belt
tensioner clockwise until belt can be installed onto the tensioner pulley. Slowly release belt
tensioner. 3. Verify belt is properly routed and engaged on all pulleys.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1518
4. Install splash shield and lower vehicle.
Power Steering Belt
Refer to Drive Belt, Alternator for procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1519
Drive Belt: Service and Repair Cleaning and Inspection
Serpentine Drive Belt Wear Patterns
When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt
from rib to rib, are considered normal. These are not reasons to replace the belt. However, cracks
running along the rib (not across) are not normal. Any belt with cracks running along the rib must
be replaced. Also replace the belt if it has excessive wear, frayed cords, or severe glazing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Page 1520
Belt Tension Gauge 7198
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt Tensioner > Component Information > Specifications
Drive Belt Tensioner: Specifications
Accessory Drive Belt Tensioner Assembly Fastener 45 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Adjustments
Engine Mount: Adjustments
1. Remove the load on the engine motor mounts by carefully supporting the engine and
transmission assembly with a floor jack. 2. Loosen the right engine mount insulator vertical fastener
and the fore and aft fasteners, and the front engine mount bracket to front crossmember
screws.
3. Pry the engine right or left as required to achieve the proper drive shaft assembly length. Refer
to Transmission and Drivetrain for driveshaft
identification and related assembly length measuring.
4. Tighten engine mounts and fasteners in the following order:
a. Right engine mount insulator vertical bolts to 102 Nm (75 ft. lbs.) and the fore and aft bolts to
150 Nm (110 ft. lbs.). b. Front engine mount screws to 54 Nm (40 ft. lbs.) the clearance between
the snubbers and the engine should be 2 mm (0.078 inch) each side. c. Left engine mount through
bolt to 75 Nm (55 ft. lbs.).
5. Recheck driveshaft length.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Front Mount
Engine Mount: Service and Repair Front Mount
FRONT MOUNT
REMOVAL
1. Support the engine and transmission assembly with a floor jack so it will not rotate.
Engine Mount-Front
2. Remove the front engine mount through bolt from the insulator and front crossmember mounting
bracket. 3. Remove six screws from air dam to allow access to the front mount screws. 4. Remove
the front engine mount screws and remove the insulator assembly. 5. Remove the front mounting
bracket, if necessary.
INSTALLATION
1. Reverse removal procedure for installation and tighten fasteners (Fig. 24) to the following torque.
- (A), (C) and (D) to 68 Nm (50 ft. lbs.)
- (B) to 102 Nm (75 ft. lbs.)
- (E) to 54 Nm (40 ft. lbs.)
2. Install six screws to air dam and tighten to 12 Nm (105 inch lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Front Mount > Page 1529
Engine Mount: Service and Repair Left Mount
LEFT SIDE MOUNT
REMOVAL
1. Raise vehicle on hoist and remove left front wheel. 2. Support the transmission with a
transmission jack. 3. Remove the insulator through bolt from the mount. 4. Remove the
transmission mount fasteners and remove mount.
INSTALLATION
1. Reverse removal procedure for installation. 2. Tighten mount to transmission bolts to 55 Nm (40
ft. lbs.).
Engine Mounting-Left
3. Tighten through bolt to 75 Nm (55 ft. lbs.). 4. Adjust engine mount, refer to Adjustment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Front Mount > Page 1530
Engine Mount: Service and Repair Rear Mount
REAR MOUNT
REMOVAL
1. Raise vehicle on hoist. 2. Support the transmission with a transmission jack so it will not rotate.
3. Remove the insulator through bolt from the mount and rear suspension crossmember. 4.
Remove the four transmission mount fasteners and remove the mount.
INSTALLATION
Engine Mounting-Rear
1. Reverse the removal procedure for installation. Tighten through bolt to 75 Nm (55 ft. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Front Mount > Page 1531
Engine Mount: Service and Repair Right Mount
RIGHT SIDE MOUNT
REMOVAL
NOTE: Right mount should only be serviced as an assembly to prevent noise, vibration and
harshness concerns.
1. Remove the purge duty solenoid and wiring harness from engine mount.
Engine Mount-Right
2. Remove the two right engine mount insulator vertical fasteners and loosen the horizontal
fastener, do not remove the large nut on the end of the
core from frame rail.
3. Remove the load on the engine motor mounts by carefully supporting the engine and
transmission assembly with a floor jack. 4. Remove the vertical and horizontal fasteners from the
engine side bracket. Remove the engine mount assembly.
INSTALLATION
1. Reverse removal procedure for installation. Tighten assembly in the following order: a. Engine
mount to rail fasteners to 68 Nm (50 ft. lbs.). b. The vertical engine fastener to 102 Nm (75 ft. lbs.).
c. The horizontal fastener to 150 Nm (111 ft. lbs.). 2. Install the purge duty solenoid and wiring
harness to the engine mount. 3. Adjust engine mount, refer to Adjustment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Front Mount > Page 1532
Engine Mount: Service and Repair Rubber Insulators
ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) is adjustable to allow right/left drive train adjustment in relation to
drive shaft assembly length.
Check and reposition right engine mount insulator. See Adjustments. Adjust drive train position, if
required, for the following conditions: a. Drive shaft distress. b. Any front end structural damage
(after repair). c. Insulator replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-99 > Jun > 99 >
Serpentine Belt - Loss of Power Steering Assist
Idler Pulley: Customer Interest Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-99 > Jun > 99 >
Serpentine Belt - Loss of Power Steering Assist > Page 1541
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-99 > Jun > 99 >
Serpentine Belt - Loss of Power Steering Assist > Page 1542
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-99 > Jun > 99 >
Serpentine Belt - Loss of Power Steering Assist > Page 1543
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist
Idler Pulley: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist > Page 1549
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist > Page 1550
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist > Page 1551
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 21-06-99
> Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 21-06-99
> Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1557
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idler Pulley: > 21-06-99
> Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1563
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Minimum Pressure at Idle (Engine Fully Warmed Up)*
............................................................................................................................. 34.47 kPa (5 psi) At
3000 rpm .............................................................................................................................................
....................................... 205-551 kPa (30-80 psi) Oil Filter Bypass Valve Setting
...........................................................................................................................................................
62-103 kPa (9-15 psi) Oil Filter Type ...................................................................................................
..................................................................................................... Full Flow Oil Pressure Switch
Actuating Pressure (Min)
........................................................................................................................................ 14-28 kPa
(2-4 psi)
CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3,000 rpm.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications > Page 1568
Engine Oil Pressure: Testing and Inspection
CHECKING ENGINE OIL PRESSURE
Checking Oil Pump Pressure
Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5
psi.) at idle or 205 to 551 kPa (30 to 80 psi.) at 3000 RPM. 1. Remove pressure sending unit and
install oil pressure gauge.
CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM.
2. Warm engine at high idle until thermostat opens.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug >
Component Information > Specifications
Engine Oil Drain Plug: Specifications
Drain Plug 20 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
Without Filter Change ..........................................................................................................................
............................................................. 3.8L (4.0 Qt)
Capacity shown is without filter. When replacing filter, additional oil may be needed.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 1576
Engine Oil: Fluid Type Specifications
Engine Oil
API Classification .................................................................................................................................
........................................... SH or SH/CD or Above Above 0°F (-18°C)..............................................
........................................................................................................................................................
10W-30 Below 32°F (0°C)....................................................................................................................
..................................................................................... 5W-30
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 1577
Engine Oil: Service Precautions
SAFETY PRECAUTIONS
WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer.
Avoid prolonged and repeated contact with oils, particularly used engine oils.
- Wear protective clothing, including impervious gloves where practicable.
- Do not put oily rags in pockets.
- Avoid contaminating clothes, particularly underpants, with oil.
- Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be
cleaned regularly.
- First Aid treatment should be obtained immediately for open cuts and wounds.
- Use barrier creams, applying them before each work period, to help the removal of oil from the
skin.
- Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help).
Preparations containing lanolin replace the natural skin oils which have been removed.
- Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin.
- If skin disorders develop, obtain medical advice without delay.
- Where practicable, degrease components prior to handling.
- Where there is a risk of eye contact, eye protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash facility should be provided.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Specifications
Oil Filter: Specifications
Oil Filter Bypass Valve Setting 9 - 15 psi
Oil Filter Type Full Flow
Oil Pressure Switch Actuating Pressure (Min.) 2 - 4 psi
Oil Filter Attaching Nipple 30 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Specifications > Page 1581
Oil Filter: Service and Repair
Oil Filter
CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the
remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can to
the base is reinforced by the base plate.
1. Using suitable oil filter wrench, turn filter counterclockwise to remove from base. Properly discard
filter. 2. Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new filter with
clean engine oil. 4. Install new filter until gasket contacts base. Tighten filter 1 turn or 20 Nm (15 ft.
lbs.). Use filter wrench if necessary. 5. Start engine and check for leaks.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator >
Component Information > Testing and Inspection
Oil Level Warning Indicator: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications
Oil Pan: Specifications
Bolts 105 in.lb
Drain Plug 20 in.lb
Level Sensor Plug 30 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Removal and Installation
Oil Pan: Service and Repair Removal and Installation
REMOVAL
1. Disconnect negative cable from battery and remove engine oil dipstick. 2. Raise vehicle on hoist
and drain engine oil. 3. Remove bending brace to transaxle attaching bolt. 4. Remove bolts
attaching dust cover to transaxle housing. Lower dust cover to gain access to oil pan bolts. 5.
Remove oil pan screws and remove oil pan.
INSTALLATION
Oil Pan Sealing
1. Clean surfaces and apply a 1/8 inch bead of Mopar(R) Silicone Rubber Adhesive Sealant or
equivalent, at the parting line of the chain case cover
and the rear seal retainer.
Oil Pan Gasket Installation
2. Use a new pan gasket. 3. Install pan and tighten screws to 12 Nm (105 in. lbs.). 4. Install dust
shield and bending brace to transaxle housing. 5. Lower vehicle and install oil dipstick. 6. Connect
negative cable to battery. 7. Fill crankcase with oil to proper level.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Removal and Installation > Page 1590
Oil Pan: Service and Repair Cleaning and Inspection
1. Clean oil pan in solvent and wipe dry with a clean cloth. Clean all gasket material from mounting
surfaces of pan and block. 2. Inspect oil drain plug and plug hole for stripped or damaged threads
and repair as necessary.
Install a new drain plug gasket. Tighten to 27 Nm (20 ft. lbs.).
3. Inspect oil pan mounting flange for bends or distortion. Straighten flange if necessary. 4. Clean
oil screen and pipe in clean solvent. Inspect condition of screen.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge >
Component Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Specifications
Oil Pressure Sender: Specifications
Oil Pressure Gauge Sending Unit 60 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Specifications > Page 1597
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Specifications > Page 1598
Oil Pressure Sender: Diagrams
Engine Oil Pressure Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning
Lamp/Indicator > Component Information > Testing and Inspection
Oil Pressure Warning Lamp/Indicator: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Minimum Pressure at Idle (Engine Fully Warmed Up)*
............................................................................................................................. 34.47 kPa (5 psi) At
3000 rpm .............................................................................................................................................
....................................... 205-551 kPa (30-80 psi) Oil Filter Bypass Valve Setting
...........................................................................................................................................................
62-103 kPa (9-15 psi) Oil Filter Type ...................................................................................................
..................................................................................................... Full Flow Oil Pressure Switch
Actuating Pressure (Min)
........................................................................................................................................ 14-28 kPa
(2-4 psi)
CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3,000 rpm.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications > Page 1606
Engine Oil Pressure: Testing and Inspection
CHECKING ENGINE OIL PRESSURE
Checking Oil Pump Pressure
Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5
psi.) at idle or 205 to 551 kPa (30 to 80 psi.) at 3000 RPM. 1. Remove pressure sending unit and
install oil pressure gauge.
CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM.
2. Warm engine at high idle until thermostat opens.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
INTAKE MANIFOLD:
Lower Intake Mounting Bolts
......................................................................................................................................................... 23
Nm (200 inch lbs.) Upper Plenum Bolts ..............................................................................................
.......................................................................... 28 Nm (250 inch lbs.) Plenum Support Bracket .......
..............................................................................................................................................................
.. 54 Nm (40 ft. lbs.)
TORQUE SEQUENCE:
Intake Manifold Bolts Location And Tightening Sequence
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection
Intake Manifold: Service and Repair Cleaning and Inspection
INSPECTION
Check for: ^
Damage and cracks of each section.
^ Clogged water passages in end cross-overs (if equipped).
^ Check for cylinder head mounting surface distortion using a straightedge and thickness gauge.
CLEANING
Remove the gasket material from the manifold surfaces. Be careful not to gouge or scratch the
sealing surface.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1612
Intake Manifold: Service and Repair Intake Manifold Replacement
Removal
1. Remove windshield wiper module.
2. Perform fuel system pressure release procedure (before attempting any repairs).
3. Drain cooling system.
4. Remove air inlet resonator to throttle body hose assembly.
5. Remove throttle cable. Remove wiring harness from throttle cable bracket.
6. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors
from throttle body.
7. Remove EGR transducer connector.
8. Remove vacuum hose harness from throttle body.
9. Remove PCV and brake booster hoses from air intake plenum.
10. Disconnect MAP Sensor electrical connection.
11. Remove EGR tube flange from intake plenum.
12. Remove vacuum harness connectors from intake plenum.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1613
13. Remove cylinder head to intake plenum strut.
14. Remove the engine mounted ground strap.
15. Remove the fuel hose quick connect fitting from the fuel line by using an open end wrench
pushing in on the plastic ring located on the end of the fittings. Gently pull the fitting from the fuel
line.
CAUTION: Wrap a shop towel around hoses to catch any gasoline spillage during removal.
16. Remove Direct Ignition System (DIS) coils and generator bracket to intake manifold bolt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1614
17. Remove bolts from generator to intake manifold bracket. Loosen top generator mounting bolt,
and move bracket up so intake manifold can clear mounting studs.
18. Remove intake manifold bolts and remove the manifold.
19. Cover intake manifold with suitable cover when servicing.
20. Remove vacuum harness connector from Fuel Pressure Regulator.
21. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread the retainer
bracket to allow fuel tube removal clearance.
22. Disconnect cam sensor and coolant temperature sensor.
23. Remove fuel injector wiring clip from intake manifold water tube.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1615
24. Remove fuel rail. Be careful not to damage the rubber injector O-rings upon removal from their
ports.
Intake Manifold Bolts Location And Tightening Sequence
25. Remove upper radiator hose, bypass hose and rear intake manifold hose.
26. Remove intake manifold bolts. Remove intake manifold.
27. Inspect and clean manifold.
WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE
PERSONAL INJURY, HANDLE WITH CARE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1616
28. Remove intake manifold seal retainers screws. Remove intake manifold gasket.
Installation
1. Clean all surfaces of cylinder block and cylinder heads.
2. Place a drop (approximately 1/4 inch diameter) of Mopar (R) Silicone Rubber Adhesive Sealant
or equivalent, onto each of the four manifold to cylinder head gasket corners.
3. Carefully install the new intake manifold gasket. Torque end seal retainer screws to 12 Nm (105
inch lbs.).
Intake Manifold Bolts Location And Tightening Sequence
4. Install intake manifold and bolts and torque to 1 Nm (10 inch lbs.). Then torque bolts to 22 Nm
(200 inch lbs.) in sequence shown. Then torque again to 22 Nm (200 inch lbs.). After intake
manifold is in place, inspect to make sure seals are in place.
5. Make sure the injector holes are clean and all plugs have been removed.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1617
6. Lube injector O-ring with a drop of clean engine oil to ease installation.
7. Put the tip of each injector into their ports. Push the assembly into place until the injectors are
seated in the ports.
8. Install the fuel rail attaching bolts and torque to 22 Nm (200 inch lbs.).
9. Install fuel tube retaining bracket screw and torque to 4 Nm (35 inch lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1618
10. Connect cam sensor and coolant temperature sensor.
11. Connect fuel pressure regulator vacuum line.
12. Remove covering on lower intake manifold and clean surface.
13. Place the new intake manifold gasket on lower manifold. Put upper manifold into place and
install bolts and nuts finger tight.
NOTE: At no time should the studs be replaced with a bolt and washer.
14. Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold
strut bolts. (Do not torque.)
15. Torque intake manifold bolts to 28 Nm (250 inch lbs.) following torque sequence.
16. Torque generator bracket to intake manifold bolt to 54 Nm (40 ft. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1619
17. Torque the cylinder head to intake manifold strut bolts to 54 Nm (40 ft. lbs.).
18. Connect ground strap and MAP sensor electrical connectors.
19. Connect vacuum harness to intake plenum.
20. Using a new gasket, connect the EGR tube flange to the intake manifold and torque to 22 Nm
(200 inch lbs.).
21. Clip wiring harness into the hole in the throttle cable bracket.
22. Connect the wiring connectors to the Throttle Position Sensor (TPS) and Automatic Idle Speed
(AIS) motor.
23. Connect vacuum harness to throttle body.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1620
24. Install the Direct Ignition System (DIS) coils. Torque fasteners to 12 Nm (105 inch lbs.).
25. Lubricate the end of the chassis fuel tube with 30 WT oil. Connect fuel supply hose to chassis
fuel tube assembly. Pull back on the quick connect fitting to ensure complete insertion.
26. Install throttle cable.
27. Connect fuel injector wiring harness.
28. Install air cleaner and hose assembly.
29. Connect negative battery cable.
30. With the Diagnostic Readout Box (DRB) Scan Tool use Auto Shutdown (ASD) Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test, The ASD Relay will remain energized for 7
minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning
Indicator > Component Information > Testing and Inspection
Oil Level Warning Indicator: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge
> Component Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure
Warning Lamp/Indicator > Component Information > Testing and Inspection
Oil Pressure Warning Lamp/Indicator: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
REMOVAL
Rear Crankshaft Oil Seal-Removal
1. Insert a 3/16 flat bladed pry tool between the dust lip and the metal case of the crankshaft seal.
Angle the pry tool through the dust lip against
metal case of the seal. Pry out seal.
CAUTION: Do not permit the pry tool blade to contact crankshaft seal surface. Contact of the pry
tool blade against crankshaft edge (chamfer) is permitted.
INSTALLATION
CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installation of new seal.
Rear Crankshaft Oil Seal-Installation
1. Place Special Tool 6926-1 magnetic pilot tool on crankshaft. 2. Lightly coat seal O.D. with
Mopar(R) Stud N' Bearing Mount Adhesive or equivalent. 3. Place seal over Special Tool 6926-1
Pilot. Using Special Tool 6926-2 Installer with C-4171 Handle, drive seal into the retainer housing.
REAR CRANKSHAFT SEAL RETAINER
When retainer removal is required, remove retainer and clean engine block and retainer of old
gasket. Make sure surfaces are clean and free of oil. Install new gasket and tighten screws to 12
Nm (105 inch lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal
> Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. Remove right wheel and inner
splash shield. 3. Remove accessory drive belt.
Crankshaft Damper-Removal
4. Remove crankshaft damper.
Front Crankshaft Oil Seal-Removal
5. Remove oil seal using Special Tool 6341. Be careful not to damage the crankshaft seal surface
of cover.
INSTALLATION
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal
> Component Information > Service and Repair > Page 1638
Crankshaft Oil Seal-installation
1. Install new seal using Special Tool C-4992. 2. Place seal into opening with seal spring towards
the inside of engine. Install seal until flush with cover.
Crankshaft Damper-Installation
3. Install crankshaft pulley using plate L-4524. Thrust Bearing/washer and C-4685-C1, 5.9 inch
screw. 4. Install accessory drive belt. 5. Install inner splash shield and wheel. 6. Lower vehicle and
connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair
Valve Guide Seal: Service and Repair
Refer to Valve Spring, Service and Repair, Replacement With Engine Installed for procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Specifications
Oil Pressure Sender: Specifications
Oil Pressure Gauge Sending Unit 60 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Specifications > Page 1646
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Specifications > Page 1647
Oil Pressure Sender: Diagrams
Engine Oil Pressure Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................
.................................................... 54 Nm (40 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Specifications
Timing Chain: Specifications
Number of Links 64
Pitch 0.375 in
Width 0.750 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch
Timing Chain: Service and Repair Measuring Timing Chain Stretch
1. Place a scale next to timing chain so that any movement of chain may be measured. 2. Place a
torque wrench and socket on camshaft sprocket attaching bolt and apply torque in direction of
crankshaft rotation to take up slack: 41 Nm
(30 ft. lbs.) with cylinder head installed or 20 Nm (15 ft. lbs.) with cylinder heads removed. With a
torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be
necessary to block crankshaft to prevent rotation.
Measuring Timing Chain Wear And Stretch
3. Holding a scale even, with dimension reading as shown, along edge of chain links. Apply torque
in the reverse direction to 41 Nm (30 ft. lbs.) with
cylinder heads installed, or 20 Nm (15 ft. lbs.) with cylinder heads removed. Check amount of chain
movement.
4. Install a new timing chain, if its movement exceeds 3.175 mm (1/8 inch). 5. If chain is not
satisfactory, refer to Timing Chain Removal and Installation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch > Page 1657
Timing Chain: Service and Repair Timing Chain Replacement
REMOVAL
1. Disconnect negative cable from battery. 2. Remove timing cover. 3. Remove camshaft sprocket
attaching bolt, and timing chain with camshaft sprocket. 4. Using a suitable puller remove the
crankshaft sprocket. Be careful not to damage the crankshaft surface.
INSTALLATION
1. Position a new crankshaft sprocket on the shaft, install sprocket with suitable tool and mallet. Be
sure sprocket is seated into position. 2. Rotate crankshaft so the timing arrow is to the 12 o'clock
position. 3. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock
position. 4. Align the dark colored links with the dot on the camshaft sprocket, place timing chain
around crankshaft sprocket with the dark colored link lined
up with the dot on the sprocket and install camshaft sprocket into position.
Timing Marks Alignment
5. Use a straight edge to check alignment of timing marks. 6. Install camshaft bolt and washer.
Tighten to 54 Nm (40 ft. lbs.). 7. Rotate crankshaft 2 revolutions. Timing marks should line up. If
timing marks do not line up, remove cam sprocket and realign. 8. Check camshaft end play. With
new thrust plate the specification is 0.0127 to 0.304 min (0.005 to 0.012 inch). Old thrust plate
specification is
0.31 mm (0.012 inch) maximum. If not within these limits, install new thrust plate.
9. Install timing chain cover and connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Timing Chain Cas Cover Bolt-M8 x 1.25 20 ft.lb
Timing Chain Case Cover Bolt-M10 x 1.5 40 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 1661
Timing Cover: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Drain cooling system. 3. Support engine and remove
right engine mount. 4. Raise vehicle on hoist. Drain engine oil. 5. Remove oil pan and oil pump
pick-up. It may necessary to remove transaxle inspection cover. 6. Remove right wheel and inner
splash shield. 7. Remove accessory drive belt. 8. Remove A/C compressor and set aside. 9.
Remove A/C compressor mounting bracket.
Crankshaft Damper-Removal
10. Remove crankshaft damper. 11. Remove idler pulley from engine bracket.
Engine Bracket
12. Remove engine bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 1662
Timing Chain Case Cover
13. Remove cam sensor from timing chain cover. 14. Remove timing chain cover.
INSTALLATION
1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure
correct oil pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
Timing Chain Case Cover Gaskets And O-Rings
2. Use a new cover gasket, and O-rings.
Adhere new gasket to chain case cover, making sure that the lower edge of the gasket is flush to
0.5 mm (0.020 inch) past the lower edge of the cover.
3. Rotate crankshaft so that the oil pump drive flats are in the vertical position. 4. Position oil pump
inner rotor so the mating flats are in the same position as the crankshaft drive flats.
CAUTION: Make sure the oil pump is engaged on the crankshaft correctly or severe damage may
result.
5. Install cover onto crankshaft. 6. Install timing chain cover screws and torque to 27 Nm (20 ft.
lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 1663
Crankshaft Oil Seal-Installation
7. Install crankshaft oil seal.
Crankshaft Damper-Installation
8. Install crankshaft damper. 9. Install engine bracket and torque fasteners to 54 Nm (40 ft. lbs.).
10. Install idler pulley on engine bracket. 11. Install cam sensor. 12. Install A/C compressor
mounting bracket. 13. Install A/C compressor. 14. Install accessory drive belt. 15. Install inner
splash shield and wheel. 16. Install oil pump pick-up, oil pan, and transaxle inspection cover, if
removed. 17. Install engine mount. 18. Fill crankcase with oil to proper level. 19. Fill cooling
system. 20. Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications
Fuel Pressure: Pressure, Vacuum and Temperature Specifications
Fuel Pressure
Key On, Engine Off ..............................................................................................................................
......................................... (approx.) 338 kPa (49 psi)
Note: Using the DRB Scan Tool, access ASD Fuel System Test. The ASD Fuel System Test will
activate the fuel pump and pressurize the system.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain
energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off
position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 1669
Fuel Pressure: Capacity Specifications
Information not supplied by the manufacturer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications
Minimum Air Flow Idle Odometer <= 1000 Miles .................................................................................
.................................................................................................. 525-875 rpm Odometer >= 1000
Miles ....................................................................................................................................................
............................... 575-875 rpm
Note: Idle speed range achieved through Minimum Air Flow Idle Test
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > Page 1673
Idle Speed: Testing and Inspection
1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2.
Ensure that all accessories are off. 3. Shut off engine.
PCV Valve
4. Disconnect the PCV valve hose from the intake manifold nipple. 5. Cap the PCV valve nipple. 6.
Air Metering Fitting 6457
a. Install Air Metering Fitting 6457 (0.125 in. orifice) to the intake manifold PCV nipple. b.
Disconnect the idle purge line from the throttle body nipple.
7.
a. Cap the 3116 inch nipple. b. Connect the DRB scan tool to the data link connector.
8. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one
180°F cycle. 9. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen.
10. The following will then occur:
- Idle air control motor will fully close.
- Idle spark advance will become fixed.
- DRB scan tool displays engine rpm.
11. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum
air-flow is set correctly.
IDLE SPECIFICATION Odometer Reading = Idle RPM Below 1000 Miles = 525-875 RPM Above
1000 Miles = 575-875 RPM
12. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows:
a. Remove the throttle body from engine.
WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR
BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES
OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING
CLEANER.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > Page 1674
b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle body.
c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and
manifold side of the throttle blade. The edges of the
throttle blade and portions of the throttle bore that are closest to the throttle blade when closed,
must be free of deposits.
d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f.
Install throttle body on manifold.
g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is
not caused by the throttle body.
13. Shut off engine. 14. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple.
Reinstall the PCV valve hose. 15. Uncap the throttle body idle purge nipple and connect the idle
purge line. 16. Remove DRB scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
REMOVAL
Air Inlet Resonator
1. Remove 2 screws and air inlet resonator. 2. Loosen 3 clamps holding air cleaner housing halves
together.
Air Cleaner Housing (Left Side)
3. Remove left side of air cleaner housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1679
Air Cleaner Element
4. Remove element from air cleaner housing.
INSTALLATION
1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4.
Install hoses and air inlet resonator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1684
Fuel Pressure Release: Service and Repair
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap.
Fuel Pressure Test Port
Releasing Fuel Pressure
3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel
pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other
end of hose C-4799-1 to
fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container.
Fuel gauge C-4799-B contains hose C-4799-1.
5. Replace Pressure test port cap when finished doing pressure test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Firing Order
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Specifications
Ignition Cable: Specifications
Cable = Maximum Resistance
#1 = 18.5 K Ohms
#2 = 15.5 K Ohms
#3 = 20.4 K Ohms
#4 = 21.2 K Ohms
#5 = 27.7 K Ohms
#6 = 26.7 K Ohms
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Specifications > Page 1695
Ignition Cable: Description and Operation
DESCRIPTION
The spark plug cables and spark plug boots are made from high temperature silicon materials. The
spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The
heat shields slide over the spark plug boots. The notches on the heat shields ensure the spark plug
boot and shield twist together during spark plug boot removal. They also identify proper heat shield
installation on the boot for service. Refer to Spark Plug Cable Replacement. All spark plug cable
leads are properly identified with cylinder numbers. The inside of the spark plug boot is coated with
a special high temperature silicone grease for greater sealing and to minimize boot bonding to the
spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature
plastic material. Under normal driving conditions, the spark plug cables have a recommended
service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles
for severe driving conditions per schedule B.
The spark plug heat shield can be reused if an ignition cable is replaced due to failure. Never reuse
heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing.
Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. The
bottom of the spark plug heat shield must make contact with the spark plug hex.
The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not
touch the coil mounting bolt to avoid abrasion/dielectric failures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Specifications > Page 1696
Ignition Cable: Service and Repair
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the ignition cables.
Spark Plug Boot/Heat Shield Orientation
The spark plug boot heat shield needs to be installed correctly on the boot before being installed on
the engine. If it is not installed correctly engine misfire would occur.
Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly.
Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely
important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield
must make contact with the spark plug socket hex.
CAUTION: Never coat the inside of spark plug boots with silicone grease. Some types of silicone
grease can damage the ignition cable conductor.
Spark Plug Cables # 3 And # 5
REMOVAL
1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the
spark plug. Twist the boot slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle.
This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug
insulator clean with a dry cloth before installation.
3. Remove the cable from the retaining bracket. Make sure that they are also detached from the
rear retaining clip mounted on the rear of the intake
manifold.
INSTALLATION
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated. A click sound should be heard
or terminal engagement is felt when the terminals are properly attached.
2. Install the cable into the retaining bracket. Make sure that they are also attached to the rear
retaining clip mounted on the rear of the intake
manifold.
3. Install the resonator.
Spark Plug Cable # 1
REMOVAL
1. Remove the accessory drive belt. 2. Remove the four bolts from the upper half of the generator
bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as
possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle.
This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug
insulator clean with a dry cloth before installation.
5. Remove the cable from the retaining bracket.
INSTALLATION
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated. A click sound should be heard
or terminal engagement is felt when the terminals are properly attached.
2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install
the accessory drive belt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications
Spark Plug: Specifications
Electrode Gap ......................................................................................................................................
.................................. 1.21-1.34 mm (0.048-0.053 in) Torque .............................................................
.............................................................................................................................................. 28 Nm
(20 ft lb)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 1700
Spark Plug: Application and ID
Spark Plug ...........................................................................................................................................
............................................................... RN14PMP5 Thread .............................................................
................................................................................................................................................ (14mm)
3/4 in.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 1701
Spark Plug: Description and Operation
SPARK PLUGS RESISTER
DESCRIPTION All engines use resistor spark plugs. They have resistance values ranging from
6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester.
Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Setting Spark Plug Electrode Gap
Refer to the Specifications for gap and type of spark plug.
SPARK PLUGS PLATINUM
DESCRIPTION The engine utilize platinum spark plugs. Refer to the maintenance schedule.
All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000
ohms when checked with at least a 1000 volt spark plug tester.
Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Platinum Pads
The spark plugs are double platinum and have a recommended service life of 100,000 miles for
normal driving conditions per schedule A. The spark plugs have a recommended service life of
75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both
electrode ends as shown. Extreme care must be used to prevent spark plug cross threading,
mis-gaping and ceramic insulator damage during plug removal and installation.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 1702
Spark Plug: Testing and Inspection
Spark Plug Condition
Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken
porcelain insulators. Keep plugs arranged in the order in which they were removed from the
engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended.
Normal Operating Conditions
Normal Operation And Cold (Carbon) Fouling
The few deposits present will be probably light tan or slightly gray in color with most grades of
commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average
more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation for non
platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, and
then reinstalled.
CAUTION: Never attempt to tile the electrodes or use a wire brush for cleaning platinum spark
plugs. This would damage the platinum pads which would shorten spark plug life.
Some fuel refiners in several areas of the United States have introduced a manganese additive
(MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark
plug with a rust colored deposit. The rust color deposits can be mis diagnosed as being caused by
coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits.
Cold Fouling (Carbon Fouling) Cold fouling is sometimes referred to as carbon fouling because the
deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a
set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set
may be caused by a clogged air cleaner.
Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough
operating temperature during short operating periods. Replace carbon fouled plugs with new spark
plugs.
Fuel Fouling A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition
is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air
and reinstall them in the engine.
Oil Fouling A spark plug that is coated with excessive wet oil is oil fouled. In older engines, wet
fouling can be caused by worn rings or excessive cylinder wear. Break-in fouling of new engines
may occur before normal oil control is achieved. Replace oil fouled spark plugs with new ones.
Oil Or Ash Encrusted
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 1703
Oil Or Ash Encrusted
If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the
combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of
spark plugs. Ash encrusted spark plugs can be cleaned and reused.
High Speed Miss When replacing spark plugs because of a high speed miss condition; wide open
throttle operation should be avoided for approximately 80 km (50 miles) after installation of new
plugs. This will allow deposit shifting in the combustion chamber to take place gradually and avoid
plug destroying splash fouling shortly after the plug change.
Electrode Gap Bridging
Electrode Gap Bridging
Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits
accumulate on the spark plugs during continuous stop-and-go driving. When the engine is
suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between
the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be
cleaned and reused.
Scavenger Deposits
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 1704
Scavenger Deposits
Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a
normal condition caused by chemical additives in certain fuels. These additives are designed to
change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that
accumulation on the ground electrode and shell area may be heavy but the deposits are easily
removed. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and
reused.
Chipped Electrode Insulator
Chipped Electrode Insulator
A chipped electrode insulator usually results from bending the center electrode while adjusting the
spark plug electrode gap. Under certain conditions, severe detonation also can separate the
insulator from the center electrode. Spark plugs with chipped electrode insulators must be
replaced.
Preignition Damage
Preignition Damage
Excessive combustion chamber temperature can cause preignition damage. First, the center
electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively
deposit free. Determine if the spark plugs are the correct type, as specified on the VECI label, or if
other operating conditions are causing engine overheating.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 1705
Spark Plug Overheating
Spark Plug Overheating
Overheating is indicated by a white or gray center electrode insulator that also appears blistered.
The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of
operation. This suggests that a plug with a cooler heat range rating should be used. Over
advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug
overheating.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 1706
Spark Plug: Service and Repair
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
server injury/burns and can cause damage to the ignition cables.
Spark Plug Boot/Heat Shield Orientation
Use extreme care when removing and installing the spark plug cables. The spark plug boot heat
shield needs to be installed correctly on the boot before being installed on the engine. If it is not
installed correctly engine misfire would occur.
Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly
Spark Plug # 3 AND # 5
REMOVAL
1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen
bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as
close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with
the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug
boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation.
Wipe spark plug insulator]ator clean with a dry cloth before installation.
6. Remove spark plug
INSTALLATION
1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables,
make sure spark plug insulator and terminals are fully seated. A click sound should be heard or felt
when
the terminals are properly attached.
3. Install the cable into the retaining bracket. Make sure that they are also attached to the rear
retaining clip mounted on the rear of the intake
manifold.
4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6.
Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator.
Spark Plug # 1
REMOVAL
1. Remove the accessory drive belt. 2. Remove the 4 bolts from the upper half of the generator
bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as
possible to the spark plug. Twist the boot/shield assembly slightly to break its seal with
the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug
boot at an angle. This could damage the spark plug insulator, terminal, or the insulation. Wipe
spark plug insulator clean with a dry cloth before installation.
5. Remove spark plug
INSTALLATION
1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables,
make sure the coil or spark plug insulator and terminals are fully seated. A click sound should be
heard or
felt when the terminals are properly attached.
3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the
accessory drive belt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
Cylinder Compression Pressure:
Minimum 100 psi with no more than 25% variance between cylinders.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 1710
Compression Check: Testing and Inspection
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions.
Ensure the battery is completely charged and the engine starter motor is in good operating
condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traffic and other forms of congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators: fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For Direct
Ignition System, disconnect the coil connector.
5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage. Record
this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than
(689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended compression pressures are to be used only as a guide
to diagnosing engine problems. An engine should not be disassembled to determine the cause of
low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test
resistance of spark plug cables. Refer to Powertrain Management. 13. Test coil output voltage,
primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at
idle and different RPM ranges.
Refer to Powertrain Management for Specifications.
15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation
system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and
therefore does not require adjustment.
See "Rocker Arm: Service and Repair" for further information.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Mounting Bolts .....................................................................................................................................
............................................... 12 Nm (105 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 1717
Water Pump: Description and Operation
The pump has a die cast aluminum body and a stamped steel impeller. It bolts directly to the chain
case cover, using an O-ring for sealing. It is driven by the back surface of the Poly-V Drive Belt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 1718
Water Pump: Testing and Inspection
Replace the water pump if it has any of the following defects: 1. Damage or cracks on the pump
body. 2. Coolant leaks: If the seal is leaking, this will be evident by traces of thick deposits of
greenish-brown dried glycol running down the pump body
and components below. A thin black stain below pump weep hole is considered normal operation.
3. Impeller rubs inside of chain case cover or cylinder block. 4. Excessively loose or rough turning
bearing.
NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole
(black stain on water pump body). Do not replace the water pump if this condition exists. Replace
the water pump if a heavy deposit or a steady flow of green/brown engine coolant is evident on
water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis
before replacing water pump.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Page 1719
Water Pump: Service and Repair
REMOVAL 1. Drain Cooling System. 2. Remove accessory drive belt. 3. Remove right front lower
fender shield. 4. Remove water pump pulley bolts and remove pulley.
Water Pump-3.3/3,8L Engines
5. Remove water pump mounting screws. Remove water pump. 6. Remove and discard O-ring
seal. 7. Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to
scratch or gouge sealing surface.
INSTALLATION
Water Pump Body
1. Install new O-ring into groove. 2. Install water pump to chain case cover. Tighten screws to 12
Nm (105 inch lbs.). 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley
on pump. Install screws and tighten to 30 Nm (250 inch lbs.). 5. Install accessory drive belt. 6.
Install right front lower fender shield. 7. Refill Cooling System.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
COOLING SYSTEM CAPACITY
2.0L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
............................................ 10.6 L (11.23 qts) Rear Heater ...............................................................
............................................................................................................................................. N/A
Trailer Tow
Front Heater ........................................................................................................................................
.................................................................. N/A Rear Heater ...............................................................
............................................................................................................................................. N/A
3.0L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
.............................................. 12.3 L (13.0 qts) Rear Heater ...............................................................
............................................................................................................................................. N/A
Trailer Tow
Front Heater ........................................................................................................................................
.............................................. 12.3 L (13.0 qts) Rear Heater ...............................................................
........................................................................................................................ 15.0 L (15.9 qts)
3.3/3.8L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
............................................ 12.5 L (13.23 qts) Rear Heater ...............................................................
.................................................................................................................... 15.26 L (16.13 qts)
Trailer Tow
Front Heater ........................................................................................................................................
............................................ 12.5 L (13.23 qts) Rear Heater ...............................................................
.................................................................................................................... 15.26 L (16.13 qts)
NOTE: Capacities include heater and coolant recovery tank filled to Max level.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 1725
Coolant: Fluid Type Specifications
The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle
operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide
protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a
minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be
eroded by cavitation, and cooling system components may be severely damaged by corrosion.
Maximum protection against freezing is provided with a 68% antifreeze concentration, which
prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer
temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the
specific heat of antifreeze is lower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used
Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the
corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The
deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this
temperature is hot enough to melt plastic and soften solder. The increased temperature can result
in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F).
Propylene-Glycol Formulations Should Not Be Used
Propylene-glycol formulations do not meet the required specifications. It's overall effective
temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point.
The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at
96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can
result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics
than ethylene-glycol. This can increase cylinder head temperatures under certain conditions.
Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used
Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion
inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and
propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the
freeze point will not be accurate. Both the refractive index and specific gravity differ between the
ethylene-glycol and propylene-glycol.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can
cause problems associated with 100 percent ethylene-glycol.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Page 1726
Coolant: Service Precautions
DO NOT mix green colored coolant with orange colored coolant.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Description and Operation > Description and Operation
Coolant: Description and Operation
The cooling system is designed around the coolant. The coolant must accept heat from engine
metal, in the cylinder head area near the exhaust valves. Coolant then carries this heat to the
radiator, where the tube/fin assemblies of these components can give it up to the air.
The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion
protection. Mopar(R) Antifreeze or the equivalent is recommended for best engine cooling without
corrosion, when mixed only to a freeze point of -37°C (-35°F) to -5C (-50F). If it loses color or
becomes contaminated, drain, flush, and replace with fresh properly mixed solution.
CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene
glycol and distilled water mix is recommended.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Description and Operation > Description and Operation > Page 1729
Coolant: Description and Operation Coolant Performance
Performance is measurable. For heat transfer pure water excels (Formula = 1 btu per minute for
each degree of temperature rise for each pound of water). This formula is altered when necessary
additives to control boiling, freezing, and corrosion are added as follows: ^
Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F).
^ 100 percent Glycol (.7 btu) can cause a hot engine and detonation and will lower the freeze point
to -22°C (-8°F).
^ 50/50 Glycol and Water (.82 btu) is the recommended combination that provides a freeze point of
-37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat,
temperature gauge, sending unit and heater are all designed for 50/50 glycol.
CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene
glycol and distilled water mix is recommended.
Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of
-59°C (-50°F).
CAUTION: Richer mixtures cannot be measured with field equipment. This can lead to problems
associated with 100 percent glycol.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Description and Operation > Page 1730
Coolant: Testing and Inspection
Coolant concentration should be checked when any additional coolant was added to system or
after a coolant drain, Rush and refill. The coolant mixture offers optimum engine cooling and
protection against corrosion when mixed to a freeze point of -37°C (-34°F) to -59°C (-50°F). The
use of a hydrometer or a refractometer can be used to test coolant concentration.
Hydrometers test the amount of glycol in a mixture by measuring the specific gravity of the mixture.
The higher the concentration of ethylene glycol, the larger the number of balls that will float, and
higher the freeze protection (up to a maximum of 70% by volume glycol).
Refractometers test the amount of glycol in a coolant mixture by measuring the amount a beam of
light bends as it passes through the fluid.
Some coolant manufactures use other types of glycols into their coolant formulations. Propylene
glycol is the most common new coolant. However, propylene glycol based coolants do not provide
the same freezing protection and corrosion protection and is only recommended for limited usage.
Refer to appropriate Technical Service Bulletin(s) regarding use of propylene glycol based
coolants.
CAUTION: Do not mix types of coolant. Corrosion protection will be severely reduced.
Because ethylene glycol and propylene glycol do not have the same specific gravities, the use of a
hydrometer will be inaccurate. Therefore, Special Tool 8286 refractometer, must be used when
testing coolant.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Description and Operation > Page 1731
Coolant: Service and Repair
Refer to Cooling System, Service and Repair for applicable service procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams
Radiator Cooling Fan Motor: Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 1736
Radiator Cooling Fan Motor: Description and Operation
Cooling fans are pulse width modulated variable speed fans controlled by the PCM through a solid
state relay.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 1737
Radiator Cooling Fan Motor: Testing and Inspection
Fan control is accomplished two ways. A pressure transducer on the compressor discharge line
sends a signal to the Powertrain Control Module (PCM) which will activate the fan. In addition to
this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant
temperature sensor which sends the message to the PCM. The fan will not run during cranking
until the engine starts no matter what the coolant temperature is.
CAUTION: The solid state fan relay is attached to the left frame rail near the lower radiator support.
The relay bracket, and fastener are used to dissipate heat from the relay. Ensure the relay is
properly attached to prevent the following:
- Intermittent engine overheating.
- Relay "thermal" shutdown, or relay damage.
For Diagnosis See: Powertrain Management/Computers and Control Systems/Testing and
Inspection /Diagnostic Charts/Trouble Code Tests (TC)/TC-14A Rad Fan Control Relay Circuit
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Diagrams > Page 1738
Radiator Cooling Fan Motor: Service and Repair
Fan Module
FAN MODULE
REMOVAL There are no repairs to be made to the fan or shroud assembly. If the fan is warped,
cracked, or otherwise damaged, it must be replaced as an assembly. 1. Raise the vehicle on hoist.
2. Remove the radiator outlet hose from hose retaining clip and remove clip from shroud. 3. Lower
the vehicle. Remove the air intake resonator from the throttle body and air cleaner assembly. 4.
Disconnect the cooling fan electrical connector. Connector is located on the left side of the fan
module. 5. Remove the Coolant Recovery/Reserve System (CRS) attaching screw from the upper
crossmember. 6. Remove upper grill to crossmember valence panel. 7. Disconnect the upper
radiator mounts from the crossmember. Remove the upper crossmember. 8. Remove the air
cleaner assembly. 9. Remove fan module retaining fasteners.
10. Disconnect and plug the transmission line from the radiator fitting on the left side. 11. Raise
vehicle on the hoist and remove the filter/drier, fan module and radiator mounting bolts located on
the lower right of the fan module. 12. Lower the vehicle on hoist and remove the upper fan module
to radiator retaining clips. 13. Remove the fan module from the vehicle.
INSTALLATION 1. Install fan module assembly into attaching clips on the radiator. 2. Install the
upper fan module to radiator retaining clips. 3. Raise vehicle on the hoist and install the filter/drier,
fan module and radiator mounting fasteners located on the lower right of the module. 4. Lower the
vehicle. Connect the transmission line to the radiator fitting on the lower left side. 5. Install fan
module retaining fasteners. Tighten to 12 Nm (105 inch lbs.). 6. Install the air cleaner assembly. 7.
Install the crossmember. Tighten fasteners to 12 Nm (105 inch lbs.). 9. Install the Coolant
Recovery/Reserve System (CRS) attaching screw to the upper crossmember. Tighten to 2 Nm (18
inch lbs.).
10. Install upper grill to crossmember valence panel. 11. Connect the cooling fan module electrical
connector. Connector is located on the left side of the fan module. 12. Install the air intake
resonator to the throttle body and air cleaner assembly. 13. Raise the vehicle. 14. Install outlet
hose retainer clip to the shroud. Install the radiator outlet hose to the retaining clip. 15. Lower the
vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions
Radiator Cooling Fan Motor Relay: Technical Service Bulletins Cooling System - Cooling Fan
Relay Revisions
NUMBER: 26-10-99B
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the cooling fan relay information
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions >
Page 1743
7-1
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions >
Page 1744
7-12
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions >
Page 1745
7-25
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions >
Page 1746
7-25A
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions >
Page 1747
7-25B
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan Relay Revisions >
Page 1748
14-49
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1749
Radiator Cooling Fan Motor Relay: Locations
Engine Compartment Connections - Early Build
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1750
Engine Compartment Connections - Late Build
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1751
Fan Control Module
The SSFR (Solid State Fan Relay) is located on the left front inner frame just behind the radiator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1754
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1755
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1756
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1757
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1758
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1759
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1760
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1761
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1762
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1763
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1764
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1765
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1766
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1767
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1768
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1769
Radiator Cooling Fan Motor Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1770
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1771
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1772
A/C & Heater -- Sheet 8w-42-8
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Diagrams > Page 1773
Radiator Cooling Fan Motor Relay: Description and Operation
SOLID STATE FAN RELAY-PCM OUTPUT
The radiator fan runs at a variable speed depending on coolant temperature and A/C system
pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR).
A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR.
Depending upon the amount of pulse on time, the SSFR puts out a proportional voltage to the fan
motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan
motor will be 3.6 volts.
When engine coolant reaches approximately 102 °C (215 °F) the PCM grounds the SSFR relay. If
engine coolant reaches 207 °C (225 °F) the PCM grounds the high speed ground relay and high
speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay and
high speed ground relay when coolant temperature drops to approximately 101 °C (214 °F). When
coolant temperature drops to 101 °C (214 ° F) the fan operates at low speed. The PCM
de-energizes the low speed relay when coolant temperature drops to approximately 93 °C (199 °F).
Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air
conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately
40 psi, the pressure switch opens and the fan operates at low speed.
Fan Control Module
The SSFR relay is located on the left front inner frame just behind the radiator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Temperature Sensor 7 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
1778
Coolant Temperature Sensor/Switch (For Computer): Locations
Engine Coolant Temperature Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
1779
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
1780
Coolant Temperature Sensor/Switch (For Computer): Service Precautions
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT
TEMPERATURE (ECT) SENSOR.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
1781
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT
The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40°
F to 265° F).
The engine coolant temperature sensor provides an input voltage to the PCM. As coolant
temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM.
When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The engine coolant sensor is also used for cooling fan control.
Engine Coolant Temperature Sensor
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
1782
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Engine Coolant Temperature Sensor
1. With the key off, disconnect wire harness connector from coolant temperature sensor.
Engine Coolant Temperature Sensor
2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter
should read as follows:
a. ECT STET at normal operating temperature around 200°F should read approximately 700 to
1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately
7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater
than 1 ohm, repair the wire harness as necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
1783
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT
TEMPERATURE SENSOR.
REMOVAL
1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant
sensor electrical connector. 3. Remove coolant sensor.
INSTALLATION
1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector
to sensor. 3. Fill cooling system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Temperature Sender Unit 60 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Front Heater Core
Heater Core: Service and Repair Front Heater Core
REMOVAL
1. Drain coolant system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and
Repair" See: Service and Repair 2. Remove left side lower column cover. 3. Remove steering
column assembly. Refer to: "Steering and Suspension : Steering : Steering Column : Service and
Repair" See: Steering and
Suspension/Steering/Steering Column/Service and Repair
ABS Module
4. Remove ABS module, bracket and wiring.
Interconnect And Bracket
5. Remove I/P to body harness interconnect and bracket.
Lower Silencer Boot
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Front Heater Core > Page 1791
6. Remove lower silencer boot at base of steering shaft. 7. Pinch off heater lines under the hood.
Heater Core Plate And Tubes
8. Remove heater core cover. Insert a small amount of towels under the heater core tubes.
Remove heater core plate and tubes.
Depress Clips
9. Depress heater core retaining clips.
Accelerator Pedal
10. Pull up on accelerator pedal and slide heater core past.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Front Heater Core > Page 1792
Brake Pedal
11. Depress brake pedal and remove heater core from HVAC housing.
INSTALLATION
For installation, reverse the above procedures. Install screws to retain heater core in housing.
Replace heater core tube inlet O-rings. Tighten heater core tube retaining plate to 3 ± 1 NM (27 ± 9
in. lbs.) torque.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Front Heater Core > Page 1793
Heater Core: Service and Repair Rear Heater Core
REMOVAL
1. Remove the lower right quarter trim panel. Refer to: "Body and Frame : Interior Trim : Trim Panel
: Service and Repair" See: Body and
Frame/Interior Moulding / Trim/Trim Panel/Service and Repair
Heater Core Lines
2. Isolate and disconnect lines from heater core. 3. Remove heater core retaining screws. 4.
Carefully pull the heater core and tubes up and straight out of the unit.
INSTALLATION
Filling Heater Core
For installation, reverse the above procedures. Prefill the heater core. Test for leaks and overall
performance.
NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the
vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater
core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat
opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled
completely, the following procedure can be used:
- Vehicle at room temperature.
- Engine is brought up to operating temperature.
- Front unit is OFF, temperature slides are at full HEAT position.
- Engine is at idle.
- With rear blower motor ON HIGH
- Discharge air temperature measured at the dual register located on the C-pillar base, is between
57° C to 62° C (135° and 145° F).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair
Heater Hose: Service and Repair
REMOVAL
NOTE: Review Safety Precautions and Warnings before proceeding with this operation.
1. Drain engine cooling system.
Upper Heater Hose
Lower Heater Hose
2. Loosen clamps at each end of heater hose to be removed.
CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive
force. Heater core may become damaged and leak engine coolant.
3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the
hose will not come off, slice the hose at the
connector nipple and peel off heater hose. This method will require heater hose replacement.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Temperature Gauge: Initial Inspection and Diagnostic Overview
Instrument Cluster DTC Table
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system
monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code
(DTC) will be displayed in the odometer window of the cluster.
The following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview >
Page 1802
Temperature Gauge: Component Tests and General Diagnostics
Temperature Gauge Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview >
Page 1803
Temperature Gauge Diagnosis (Part 2 Of 2)
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection
Temperature Warning Lamp/Indicator: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug >
Component Information > Service and Repair
Radiator Drain Plug: Service and Repair
REMOVAL
CAUTION: Use of pliers on draincock is not recommended. Damage may occur to part. Draincock
should not be removed unless leakage observed.
Draincock Disassembled
1. Turn the draincock stem counterclockwise to unscrew the stem. When the stem is unscrewed to
the end of the threads turn back 1/8 turn and pull
the stem from the radiator tank.
INSTALLATION
1. Push the draincock assembly body into the tank opening until it snaps into place. 2. Tighten the
draincock stem by turning clockwise until it stops.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Description and Operation
Radiator Cap: Description and Operation
The radiator is equipped with a pressure cap that releases excessive cooling system pressure,
maintaining a range of 97-124 kPa (14-18 psi).
Radiator Pressure Cap Filler Neck
The cooling system will operate at higher than atmospheric pressure. The higher pressure raises
the coolant boiling point thus, allowing increased radiator cooling capacity. There is also a vent
valve in the center of the cap. This valve also opens when coolant is cooling and contracting
allowing coolant to return to radiator from coolant reserve system tank by vacuum through
connecting hose. If valve is stuck shut, or the coolant recovery hose is pinched, the radiator hoses
will be collapsed on cool down. Clean the vent valve and inspect coolant recovery hose routing, to
ensure proper sealing when boiling point is reached.
The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to
be drawn back into the radiator from the reserve tank. If the gasket is dirty or damaged, a vacuum
may not be achieved, resulting is loss of coolant and eventual overheating due to low coolant level
in radiator and engine.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Description and Operation > Page 1814
Radiator Cap: Testing and Inspection
RADIATOR CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK
Radiator Pressure Cap Filler Neck
The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow
hose at the radiator filler neck nipple. Attach the Radiator Pressure Tool to the filler neck nipple and
pump air into the radiator. Pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and
hold pressure at 55 kPa (8 psi) minimum.
WARNING: THE WARNING WORDS "DO NOT OPEN HOT" ON THE RADIATOR PRESSURE
CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM.
TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED
WHILE THE SYSTEM IS HOT OR UNDER PRESSURE.
There is no need to remove the radiator cap at any time except for the following purposes: 1.
Check and adjust coolant freeze point. By adding or subtracting coolant through CRS bottle. 2.
Refill system with new coolant. 3. Conducting service procedures. 4. Checking for vacuum leaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY. WAIT 15 MINUTES BEFORE REMOVING
CAP. THEN PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN,
ROTATE COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE
THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE DROPS, PUSH DOWN AND REMOVE
THE CAP COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL
(TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS
RECOMMENDED.
PRESSURE TESTING RADIATOR CAP
Dip the pressure cap in water, clean any deposits off the vent valve or its seat and apply cap to end
of Radiator Pressure Tool. Working the plunger, bring the pressure to 104 kPa (15 psi) on the
gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace cap.
Pressure Testing Radiator Cap
If the pressure cap tests properly while positioned on Radiator Pressure Tool, but will not hold
pressure or vacuum when positioned on the radiator. Inspect the radiator filler neck and cap top
gasket for irregularities that may prevent the cap from sealing properly.
CAUTION: Radiator Pressure Tool is very sensitive to small air leaks that will not cause cooling
system problems. A pressure cap that does not have a history of coolant loss should not be
replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool
upside down and recheck pressure cap to confirm that cap is bad.
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Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
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INSPECTION
Hold the cap in hand, right side up. The vent valve at the bottom of the cap should open. If the
rubber gasket has swollen and prevents the valve from opening, replace the cap.
Hold the cleaned cap in hand upside down. If any light shows between vent valve and rubber
gasket, replace cap. Do not use a replacement cap that has a spring to hold the vent shut.
Replacement cap must be of the type designed for coolant reserve system with a completely
sealed diaphragm spring, and rubber gasket to seal to filler neck top surface. This design assures
coolant return to radiator.
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Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information >
Description and Operation
Radiator Hose: Description and Operation
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING
ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND
WITHOUT PUSHING DOWN ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW
FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS
PUSHING OUT COOLANT AND STEAM AND THE PRESSURE DROPS CONTINUE SERVICE.
WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM
HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING
THIS TYPE OF CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT
TENSION CLAMPS.
Spring Clamp Size Location
CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If
replacement is necessary, use only a original equipment clamp with matching number or letter.
Hose Clamp Tool
The hose clamps are removed by using Special Tool 6094 or equivalent constant tension clamp
pliers to compress hose clamp.
A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet
and outlet when loosening hoses.
Radiator hoses should be routed without any kinks and indexed as designed. The use of molded
hoses is recommended.
Make sure hoses and connectors are clean and dry before installation. Do not lubricate hoses
when installing.
Spring type hose clamps are used in all applications. If replacement is necessary, replace with the
original Mopar(R) equipment spring type clamp.
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Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan
Relay Revisions
Radiator Cooling Fan Motor Relay: Technical Service Bulletins Cooling System - Cooling Fan
Relay Revisions
NUMBER: 26-10-99B
GROUP: Miscellaneous
DATE: October, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the cooling fan relay information
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Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan
Relay Revisions > Page 1824
7-1
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Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan
Relay Revisions > Page 1825
7-12
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Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan
Relay Revisions > Page 1826
7-25
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Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan
Relay Revisions > Page 1827
7-25A
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Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan
Relay Revisions > Page 1828
7-25B
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Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Cooling System - Cooling Fan
Relay Revisions > Page 1829
14-49
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Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1830
Radiator Cooling Fan Motor Relay: Locations
Engine Compartment Connections - Early Build
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1831
Engine Compartment Connections - Late Build
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Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 1832
Fan Control Module
The SSFR (Solid State Fan Relay) is located on the left front inner frame just behind the radiator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
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Radiator Cooling Fan Motor Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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1837
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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1838
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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1839
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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1840
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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1841
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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1842
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1843
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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1844
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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1845
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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1846
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Radiator Cooling Fan Motor Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page
1851
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page
1852
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page
1853
A/C & Heater -- Sheet 8w-42-8
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 1854
Radiator Cooling Fan Motor Relay: Description and Operation
SOLID STATE FAN RELAY-PCM OUTPUT
The radiator fan runs at a variable speed depending on coolant temperature and A/C system
pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR).
A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR.
Depending upon the amount of pulse on time, the SSFR puts out a proportional voltage to the fan
motor at the lower speed. For instance, if the on time is 30 percent, then the voltage to the fan
motor will be 3.6 volts.
When engine coolant reaches approximately 102 °C (215 °F) the PCM grounds the SSFR relay. If
engine coolant reaches 207 °C (225 °F) the PCM grounds the high speed ground relay and high
speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay and
high speed ground relay when coolant temperature drops to approximately 101 °C (214 °F). When
coolant temperature drops to 101 °C (214 ° F) the fan operates at low speed. The PCM
de-energizes the low speed relay when coolant temperature drops to approximately 93 °C (199 °F).
Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air
conditioning switch closes at 285 psi ± 10 psi. When air conditioning pressure drops approximately
40 psi, the pressure switch opens and the fan operates at low speed.
Fan Control Module
The SSFR relay is located on the left front inner frame just behind the radiator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Temperature Sensor 7 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1860
Coolant Temperature Sensor/Switch (For Computer): Locations
Engine Coolant Temperature Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1861
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1862
Coolant Temperature Sensor/Switch (For Computer): Service Precautions
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT
TEMPERATURE (ECT) SENSOR.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1863
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT
The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40°
F to 265° F).
The engine coolant temperature sensor provides an input voltage to the PCM. As coolant
temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM.
When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The engine coolant sensor is also used for cooling fan control.
Engine Coolant Temperature Sensor
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1864
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Engine Coolant Temperature Sensor
1. With the key off, disconnect wire harness connector from coolant temperature sensor.
Engine Coolant Temperature Sensor
2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter
should read as follows:
a. ECT STET at normal operating temperature around 200°F should read approximately 700 to
1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately
7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater
than 1 ohm, repair the wire harness as necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1865
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT
TEMPERATURE SENSOR.
REMOVAL
1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant
sensor electrical connector. 3. Remove coolant sensor.
INSTALLATION
1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector
to sensor. 3. Fill cooling system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Temperature Sender Unit 60 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Temperature Gauge: Initial Inspection and Diagnostic Overview
Instrument Cluster DTC Table
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system
monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code
(DTC) will be displayed in the odometer window of the cluster.
The following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1873
Temperature Gauge: Component Tests and General Diagnostics
Temperature Gauge Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1874
Temperature Gauge Diagnosis (Part 2 Of 2)
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator,
Engine Cooling > Component Information > Testing and Inspection
Temperature Warning Lamp/Indicator: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications
Thermostat: Specifications
THERMOSTAT OPERATING RANGE:
Opening Temperature .........................................................................................................................
...................................................................... 192°F Full Opening Temperature .................................
......................................................................................................................................................
220°F
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 1881
Thermostat: Description and Operation
THERMOSTAT
The engine cooling thermostats are a wax pellet driven, reverse poppet choke type. They are
designed to provide the fastest warm up possible by preventing leakage through them and to
guarantee a minimum engine operating temperature of 88° to 93°C (192° to 199°F). They also
automatically reach wide open so they do not restrict flow to the radiator as temperature of the
coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant
temperature is controlled by the fan, the radiator, and the ambient temperature, not the thermostat.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 1882
Thermostat: Service and Repair
REMOVAL
1. Drain cooling system down below the thermostat level.
Thermostat, Housing, And Water Box-3.3/3.8L Engines
2. Remove thermostat housing bolts and housing. 3. Remove thermostat. Discard gasket and clean
both gasket sealing surfaces.
INSTALLATION
1. Place a new gasket (dipped in water) on the thermostat housing surface, center thermostat into
opening in the intake manifold water box. 2. Place housing and gasket over the thermostat, making
sure thermostat is in the recess provided. 3. Install housing to intake manifold and tighten bolts to
28 Nm (250 inch lbs.). 4. Refill the cooling system to the proper level.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Specifications
Thermostat Housing: Specifications Torque Specs
Torque Specs
Thermostat Housing Bolts 250 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Mounting Bolts .....................................................................................................................................
............................................... 12 Nm (105 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 1889
Water Pump: Description and Operation
The pump has a die cast aluminum body and a stamped steel impeller. It bolts directly to the chain
case cover, using an O-ring for sealing. It is driven by the back surface of the Poly-V Drive Belt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 1890
Water Pump: Testing and Inspection
Replace the water pump if it has any of the following defects: 1. Damage or cracks on the pump
body. 2. Coolant leaks: If the seal is leaking, this will be evident by traces of thick deposits of
greenish-brown dried glycol running down the pump body
and components below. A thin black stain below pump weep hole is considered normal operation.
3. Impeller rubs inside of chain case cover or cylinder block. 4. Excessively loose or rough turning
bearing.
NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole
(black stain on water pump body). Do not replace the water pump if this condition exists. Replace
the water pump if a heavy deposit or a steady flow of green/brown engine coolant is evident on
water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis
before replacing water pump.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 1891
Water Pump: Service and Repair
REMOVAL 1. Drain Cooling System. 2. Remove accessory drive belt. 3. Remove right front lower
fender shield. 4. Remove water pump pulley bolts and remove pulley.
Water Pump-3.3/3,8L Engines
5. Remove water pump mounting screws. Remove water pump. 6. Remove and discard O-ring
seal. 7. Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to
scratch or gouge sealing surface.
INSTALLATION
Water Pump Body
1. Install new O-ring into groove. 2. Install water pump to chain case cover. Tighten screws to 12
Nm (105 inch lbs.). 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley
on pump. Install screws and tighten to 30 Nm (250 inch lbs.). 5. Install accessory drive belt. 6.
Install right front lower fender shield. 7. Refill Cooling System.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Description and Operation
Catalytic Converter: Description and Operation
There is no regularly scheduled maintenance on any Chrysler catalytic converter. If damaged, the
converter must be replaced.
CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies,
extreme care should be taken with replacement parts. There are internal converter differences
required in some parts of the country.
The combustion reaction caused by the catalyst releases additional heat in the exhaust system.
Causing temperature increases in the area of the reactor under severe operating conditions. Such
conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do
not remove spark plug wires from plugs or by any other means short out cylinders of the exhaust
system if equipped with a catalytic converter. Failure of the catalytic converter can occur due to
temperature increases caused by unburned fuel igniting when passing through the converter.
The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be
used to avoid poisoning the catalyst core. Do not allow engine to operate at fast idle for extended
periods (over 5 minutes). This condition may result in excessive exhaust system and floor pan
temperatures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Description and Operation > Page 1896
Catalytic Converter: Service and Repair
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY
HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE
EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN
WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.
REMOVAL
1. Remove muffler and tailpipe assembly.
Downstream Oxygen Sensor
2. Disconnect downstream oxygen sensor from the catalytic converter pipe. 3. Remove catalytic
converter to exhaust manifold attaching fasteners. 4. Remove catalytic converter and gasket.
INSTALLATION
1. Position new gasket onto manifold flange and install catalytic converter. Tighten fasteners to 28
Nm (250 inch lbs.). 2. Connect downstream oxygen sensor. 3. Install muffler and tailpipe assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Specifications
Exhaust Manifold: Specifications
Manifold to Cylinder Head Bolts
........................................................................................................................................................ 23
Nm (200 inch lbs.) Fastener ................................................................................................................
............................................................................... 23 Nm (200 inch lbs.) Stud ..................................
..............................................................................................................................................................
..... 23 Nm (200 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Service and Repair > Removal and Installation
Exhaust Manifold: Service and Repair Removal and Installation
REMOVAL
1. Disconnect battery negative cable. 2. Remove accessory drive belt. 3. Remove generator. 4.
Raise vehicle and disconnect exhaust pipe from rear (cowl side) exhaust manifold at flex-joint. 5.
Disconnect downstream oxygen sensor connector. 6. Lower exhaust system to gain access to rear
manifold.
EGR, Heated Oxygen Sensor And Generator/Power Steering Strut
7. Separate EGR tube from rear manifold and disconnect heated oxygen sensor lead wire. 8.
Remove heat shield from rear engine mount. 9. Remove generator/power steering support strut.
10. Remove bolts attaching crossover pipe to manifold. 11. Disconnect up stream oxygen sensor
connector. 12. Remove bolts attaching rear manifold to cylinder head and remove manifold.
Heat Shield-Front
13. Lower vehicle and remove screws attaching front heat shield to front manifold.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Service and Repair > Removal and Installation > Page 1902
Crossover Pipe
14. Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to
cylinder head. Remove assemblies. 15. Inspect and clean manifold. Refer to Cleaning and
Inspection for procedures.
INSTALLATION
1. Install rear exhaust manifold and tighten attaching bolts to 23 Nm (200 inch lbs.). 2. Install
generator.
NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. Replace if
necessary.
3. Using new gasket, attach crossover pipe to exhaust manifold and tighten bolts to 54 Nm (40 ft.
lbs.). 4. Connect oxygen sensor lead. 5. Install EGR tube and generator/power steering strut. 6.
Install front exhaust manifold and tighten attaching bolts to 23 Nm (200 inch lbs.). 7. Attach exhaust
crossover with a new gasket and tighten fasteners to 54 Nm (40 ft. lbs.). 8. Connect up stream
oxygen sensor connector. 9. Install exhaust system.
10. Attach exhaust pipe to exhaust manifold using new gasket and tighten bolts to 28 Nm (250 inch
lbs.). 11. Connect downstream oxygen sensor connector. 12. Install front manifold heat shield and
tighten attaching screws to 12 Nm (105 inch lbs.). 13. Install accessory drive belt. 14. Connect
battery negative cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Service and Repair > Removal and Installation > Page 1903
Exhaust Manifold: Service and Repair Cleaning and Inspection
INSPECTION
Check Exhaust Manifold Mounting
Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting
surface and exhaust cross-over mounting surface with a straightedge and thickness gauge.
CLEANING
Remove the gasket material from the manifold surfaces (if equipped). Be careful not to gouge or
scratch the sealing surface.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Specifications
Exhaust Pipe: Specifications
Exhaust Crossover Pipe Fange Fastners 25 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Specifications > Page 1907
Exhaust Pipe: Service and Repair
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY
HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE
EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN
WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.
REMOVAL
1. Raise vehicle on hoist and apply penetrating oil to clamp bolts and nuts of component being
removed.
Band Clamp
Exhaust System Components
2. Loosen clamps and supports and from exhaust system to permit alignment of parts during
assembly. 3. When removing tailpipe, raise rear of vehicle to relieve body weight from rear springs
to provide clearance between pipe and rear axle parts. 4. Clean ends of pipes or muffler to assure
mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts.
When
replacement is required on any component of the exhaust system. It is important that original
equipment parts (or their equivalent) be used; ^
To insure proper alignment with other parts in the system.
^ Provide acceptable exhaust noise levels and does not change exhaust system back pressure that
could effect emissions and performance.
INSTALLATION
1. Assemble pipes, muffler support and clamp loosely to permit alignment of all parts. 2. Beginning
at front of system, align and clamp each component to maintain position and proper clearance with
underbody parts. 3. Tighten the clamp and support to the proper torques and clearances.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component
Information > Specifications
Exhaust Pipe/Muffler Hanger: Specifications
Muffler Hanger Support Clamp Fastener 150 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Specifications
Heat Shield: Specifications
Heat Shield-Muffler Fastener 23 in.lb
Heat Shield-Toe Board Fastener 23 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Specifications > Page 1914
Heat Shield: Description and Operation
Heat Shields
Heat shields are needed to protect both the vehicle and the floor pan from the high temperatures
developed near the catalytic converter and muffler.
Avoid application of rust prevention compounds or undercoating materials to exhaust system floor
pan heat shields on cars so equipped. Light over spray near the edges is permitted. Application of
coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan
temperatures and objectionable fumes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair
Muffler: Service and Repair
Refer to Exhaust Pipe for procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> Electrical - Wiring Schematics Revisions
Body Control Module: Technical Service Bulletins Electrical - Wiring Schematics Revisions
NUMBER: 26-12-99G
GROUP: Miscellaneous
DATE: December, 1999
THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revisions to the wiring schematics
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8W-44-5
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8W-44-7
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8W-45-7
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> Electrical - Wiring Schematics Revisions > Page 1928
8W-50-2
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8W-50-5
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8W-50-7
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8W-80-15
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8W-90-3
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8W-90-11
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Body Control Module: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out
Revisions
NUMBER: 26-04-99
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
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8N-4
Revision to the Body Control Module connector pin-out
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8W-80-13
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Body Control Module: Technical Service Bulletins Body Control Module - Erroneous DTC Set
NO: 18-25-98
GROUP: Vehicle Performance
DATE: Aug. 14, 1998
SUBJECT: Erroneous Body Control Module Diagnostic Trouble Code
MODELS:
1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSAXLE.
DISCUSSION:
During service diagnostic procedures, the Body Control Module (BCM) may indicate an erroneous
"EATX PRNDL NOT RECEIVED" Diagnostic Trouble Code (DTC). If this DTC exists, turn the
ignition to the ON position and determine if each PRNDL indicator in the instrument cluster
becomes boxed (all boxed at the same time) after ten seconds. If all PRNDL indicators do NOT
become boxed at the same time, the DTC is erroneous and the DTC should be cleared, it is not
necessary to replace the BCM.
NOTE:
CHRYSLER HAS NOT RECEIVED ANY REPORTS OF THIS DTC BEING SET BY AN ACTUAL
FAILURE IN THE PRNDL SYSTEM.
POLICY: Information Only
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Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics
NO: 08-40-98
GROUP: Electrical
DATE: Sept. 25, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED
DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL
VEHICLES.
MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager
DISCUSSION:
During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp
Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head
lamps.
If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at
erasing this erroneous DTC will be unsuccessful.
If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan,
Voyager and Town & Country Body Diagnostic Procedures Manual.**
POLICY: Information Only
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Body Control Module: Component Locations
Body Control Module
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Junction Block, Body Control Module
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Body Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Body Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Body Control Module: Connector Views
Body Control Module C1 (A)
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Body Control Module C2 (B)
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Junction Block
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Body Control Module Interconnect
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Body Control Module: Electrical Diagrams
BCM Block Diagram
Wiring Diagrams
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Body Control Module -- Sheet 8w-45-2
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Body Control Module -- Sheet 8w-45-3
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Body Control Module -- Sheet 8w-45-4
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Body Control Module -- Sheet 8w-45-5
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Body Control Module -- Sheet 8w-45-6
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Body Control Module -- Sheet 8w-45-7
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Body Control Module -- Sheet 8w-45-8
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Body Control Module -- Sheet 8w-45-9
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
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Body Control Module: Service Precautions
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
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Part 1 of 3
Body Control Module: Description and Operation Part 1 of 3
INTRODUCTION
Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION
AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger
protection if the vehicle is involved in a front end collision. The system is most effective when used
in conjunction with the seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. This information will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
Functional Operation Whenever the ignition key is turned to the "run" or "start" position, the airbag
control module (ACM) performs a lamp check by turning the AIRBAG warning lamp ON. The lamp
stays lit for 6 to 8 seconds, then goes off. If the lamp remains OFF, it means that the ACM has
checked the system and found it to be free of discernible malfunctions. The airbag system is
monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures in this book to find the cause of any customer complaint regarding the
AIRBAG warning lamp, such as: warning lamp does not come on at all
- warning lamp stays on
BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with
visual and audible information and controls various vehicle functions. To provide and receive
information, the module is interfaced to the vehicle's serial bus communications network (the
Chrysler Collision Detection bus, or CCD bus). This network consists of the powertrain control
module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster
(MIC), the airbag control module (ACM), the compass/mini- trip module and the controller antilock
brake (CAB) module. The BCM is operational when battery power is supplied to the module.
Ignition switch power is needed for ignition switch functions.
The body control module provides the following features: automatic door locks
- battery protection
- CCD radio
- chimes
- compass/mini-trip support
- courtesy lamps
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
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- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid
wearing down the battery if the customer leaves the parklamps or headlamps on for extended
periods of time with the ignition OFF. If the parklamp or headlamp switch remains in the active
position for more than 3 minutes, while the ignition is OFF, the parklamps and or headlamps will be
turned off and the input causing the lamps to be ON will be ignored. Once the 3 minute time-out has
elapsed the BCM will enter sleep mode. Any change in any inputs monitored by the BCM that
brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock), door ajar,
ignition, RKE actuation, etc.).
Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory
power ON) will inhibit the battery protection routine from turning OFF the exterior lamps as
described above.
Battery Protect: "Reading & Glove Box Lamps" This feature provides a battery protection scheme to
avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity
mirrors ON. The BCM provides a ground circuit for these interior lamps. This ground path is
connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters
sleep mode. Once the 15 minutes time-out has expired, any monitored input that brings the BCM
out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central
Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and
vanity mirrors to normal operation (normal operation defined as: "ON" is reading lamp and visor
vanity mirrors ON, or glove box open; "OFF" if reading lamp and visor vanity mirrors OFF, and
glove box closed).
Leaving the keys in the ignition switch, while the ignition is OFF, will not inhibit the battery
protection from turning off these interior lamps as described above. Leaving the ignition switch in
an active position (steering column unlocked, ignition ON or accessory power on) will inhibit the
battery protection routine from turning off these interior lamps as described above.
Shipping Mode By definition, shipping mode is when the IOD fuse is removed from the vehicle. The
BCM receives its primary power feed from the battery via the IOD fuse. The BCM also receives a
back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry,
courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is
reconnected or the ignition switch is turned to the run/start position.
Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which
are controlled by the body controller module (BCM). When the parklamp switch is closed to ground
the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same
parklamp power feed is also wired back into the BCM to provide the power feed for the PWM
circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and
high beam headlamp relays. The position of the hi-beam select switch will determine the mode of
operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and
low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of
operation at a time.
Auto Headlamps On vehicles equipped with the auto headlamp feature, the BCM will control the
exterior lamp operation by monitoring the mode selection switch located in the headlamp control
panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the
Electro-Chromic Rear View mirror. The mirror will determine the appropriate ambient light levels for
turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to
darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see
Headlamp Delay Feature description).
Headlamp Time Delay The headlamp Delay feature keeps the Headlamps on for 60 seconds giving
the driver and passengers security lighting when exiting the vehicle. This feature is only available
on vehicles equipped with RKE. The Headlamp Delay feature is activated by sequentially turning
off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be
turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45
second window is new for the NS body Once the headlamp delay has been activated the
headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the
ignition switch changes states.
CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and
announcement. Warning chimes are provided for dome lamps on, engine temperature lamp,
exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above
15 mph). The warning chime will sound continuously until the condition is removed or the battery
protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for
approximately six seconds or until the seat belt is fastened, The announcement chime will sound
one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar
lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the
vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the
instrument cluster warning lamp diagnostics.
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Body Control Module: Description and Operation Part 2 of 3
COMPASS/MINI-TRIP COMPUTER
The compass/mini-trip computer is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE),
instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information
needed for the traveler functions is received over the CCD bus from the body control module.
If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration.
Setting The Compass The compass/mini-trip module is self-calibrated and requires no adjustment.
The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL
will turn off after the vehicle has gone in three complete circles without stopping, in an area free of
magnetic disturbance.
If the module displays the temperature while the compass is blank or shows a false reading, the
vehicle must be demagnetized. See the service procedure.
If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module
must be replaced.
Compass Magnetic Variance Zones
Setting The Variance Variance is the difference between magnetic north and geographic north. To
determine the variance for the area you are in, refer to the following zone map provided. The
number shown for your area is the variance number for your area. 1. Set the compass/mini-trip
console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5
seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the
variance to 8 and enter the fast calibration mode.
3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP
button to set the zone number. 5. Press the US/M button and resume normal operation,
NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO
THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS.
MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular
position of the gauges, the status of all CCD indicator lamps, the status and dimming of the
mechanical instrument cluster (MIC) over the CCD bus when the ignition is in the "off,, (unlock),
"run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the
ignition is in the "OFF" (unlock), "run", or "start" positions; all other MIC features work only when
ignition is in the "run position. On transition of the ignition from the "OF"' to the "run" position, a bulb
check is performed. This consists of activating all CCD controlled indicator lamps and all VF display
segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is
moved from the PARK position, or if the engine exceeds 450 rpm.
POWER DOOR LOCK SYSTEM When the BCM receives an input for a lock request (door lock
switch, RKE, or door key cylinder switch (only with VTSS)), it will ground the lock-relay coil for a
specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1
second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door
lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The
unlock signal operates in the same fashion as the lock signal. The door Lock switches provide a
variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the
BCM will respond to that command.
Other power Door Lock features: Sliding Door Memory Lock- When the BCM receives an input for
a lock request and a sliding door is open, the BCM will turn on the lock relay
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as described above, and will turn it on again when all sliding doors are closed.NOTE: If the BCM
receives an unlock input before a sliding door is closed this action will cancel the memory lock.
Door Lock Inhibit- When the key is in the ignition and in the off position, and any door except the
rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional.
This protects against locking the vehicle with the keys still in the ignition.
Automatic Door Locks- This feature can be enabled or disabled by using either the DRBIII or
customer programming method. When enabled, all the doors will lock when the vehicle reaches a
speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15
MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH.
RKE (Remote Keyless Entry) Interface- The body control module interfaces with the RKE receiver
via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the
BCM depending on which button on the transmitter was pressed. The BCM controls the door
lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The
RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the
PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the
RKE.
The RKE module can be programmed via the DRBIII or customer programming method. The BCM
will only allow programming mode to be entered when the ignition is in the ON position, the PRNDL
is in park position, and the VTSS (if equipped) is in the disarmed mode.
Programming an RKE Transmitter
Customer Programming Method
NOTE: A VALID, PREVIOUSLY PROGRAMMED TRANSMITTER MUST BE USED.
1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition on, place the transmission
in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3.
Using the previously programmed transmitter, press and hold the unlock button for 4 to 8 seconds.
While still holding the unlock button, press the panic button, then release both buttons. The BCM
will acknowledge that it has grounded the RKE module program enable wire by sounding a single
chime tone.
4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has
accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle
(up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode
sooner, turn the ignition off.
DRB Programming 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition ON,
place the transmission in park, and make sure the vehicle theft security system (if equipped) is in
disarm mode. 3. Select Program RKE" under "Miscellaneous". If the message "BCM is in
Programming Mode" does not appear, exit and select "Program
RKE" again.
4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has
accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle
(up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode
sooner, press "Back Page".
RADIO SYSTEM There are three radio systems available this year that will be on the CCD bus.
They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the
radio remote controls in the steering wheel. They can control volume up/ down, seek up, seek
down and preset station selections. These systems also communicate with the body control
module and will set a specific code if there is a problem with the remote controls.
The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of
the 4 main quarter speakers have a built in amplifier. The I/P and pillar speakers receive their
signals from the quarter speakers. Depending on the manufacture some systems will have a
Front/Rear channel system and others will have a Left/Right channel system. If one of the main
quarter speaker audio circuits experiences a short, the other speakers on that channel will also
shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible
with the DRB, indicating which channel is effected.
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Body Control Module: Description and Operation Part 3 of 3
VEHICLE COMMUNICATION The body system consists of a combination of modules that
communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD
bus, information about the operation of vehicle components and circuits is relayed to the
appropriate module(s). Each module receives the same information about a component or circuit
as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and
the size of the wiring harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system called "bus +" (bus plus)
and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts.
In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded
messages, there is a "voltage divider network". This network consists of some modules with bias
and some with termination. Bias is the part of the voltage divider network that places both bus +
and bus - at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network
and also provides some electromagnetic protection for the bus.
NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF
THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE
OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH
DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE
COMMUNICATIONS.
Any of the following bus failure messages may be displayed. Short to Battery- Either or both of the
bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are
shorted to a 5-volt potential. Short to Ground- Either or both of the bus wires are shorted to ground
or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are
shorted together. No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly
above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules
that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus
Messages Correctly - The DRB cannot communicate over the bus and does not know why.
VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against theft.
The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle
hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the
horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an
engine "no run" feature.
Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's
door, locking the doors with the power lock, and closing the driver's door or locking the doors with
RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator
lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no
monitored systems are activated during this period, the system Will arm. If the hood ajar switch is
seen as closed circuit by the system, the indicator lamp Will remain steadily lit during the arming
process, although the system will still arm.
When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for
about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate
is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override The system will not arm if the doors are locked using the manual lock control (by hand) or if the
locks are actuated by an inside occupant after the door is closed.
When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus
to the powertrain control module that it is not OK to start the engine. The powertrain control module
then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting
down the engine (start and stall condition). The engine will not start until the system is disarmed.
To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but
keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE:
After the doors are closed, locking the doors with RKE will also arm the system.
NOTE: IF THE VTSS INDICATOR LAMP FLASHED, THE SYSTEM IS OPERATIONAL AND
VERIFIED. IF NOT, THERE MAY BE A PROBLEM WITH THE SYSTEM.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Part 1 of 3 > Page 1982
System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is
closed. 1. Rotating the key in liftgate cylinder to unlock/disarm position.
Arming/Disarming- Active arming occurs when the remote keyless entry transmitter is used to lock
the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming
sequence is completed only after all door are closed.
Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with
the key). This disarming also will halt the alarm once it has been activated.
Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle
doors. This disarming also will halt the alarm once it has been activated.
System Self-Test - NOTE: System self-test can be entered only with the DRB.
NOTE: A POWERTRAIN CONTROL MODULE FROM A VEHICLE EQUIPPED WITH A VEHICLE
THEFT SECURITY SYSTEM CANNOT BE USED IN A VEHICLE THAT IS NOT EQUIPPED WITH
A VEHICLE THEFT SECURITY SYSTEM.
If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication
with the powertrain control module possibly has been lost.
WIPER SYSTEM
Front The front wiper system provide the driver with normal wipe (low and high speeds),
intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function
via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the
on position and the ignition is turned OFF the wiper will continue to run until it reaches its park
position.
Other front wiper system features: Speed Sensitive Intermittent Wipe Mode- There are 6 individual
delay times with minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle
speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36
seconds.
Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more
than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided.
Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then
releases it, the wiper will continue to run for 2 additional wipe cycles.
Rear The rear wiper system provides the driver with continuous, intermittent, and wiper after wash
functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the
HVAC control.
DRB III (R) ERROR MESSAGES
Under normal operation, the DRB will display one of only two error messages: - User-Requested
WARM Boot or User- Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the MDS
Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error
message display:
ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD
Boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRB III (R) Does Not Power UP (Blank Screen) If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data
link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Part 1 of 3 > Page 1983
DRB Scan Tool
Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to
compensate for this condition
WARNINGS
Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is
"OFF". Failure to do so could damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair
verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or
symptom condition.
CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE
REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN
WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE
IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB.
REQUIRED TOOLS AND EQUIPMENT
DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires
ohmmeter voltmeter oil pressure gauge (0-300 psi) test light
GLOSSARY OF ACRONYMS
ACM Airbag Control Module
AECM Airbag Electronic Control Module (type of ACM)
ASDM Airbag System Diagnostic Module (type of ACM)
BCM body control module
CAB controller antilock brake
CCD Chrysler Collision Detection (vehicle communications bus)
CMTC
Compass/Mini-Trip Computer (module)
DLC data link connector (previously called "engine diagnostic connector")
DR driver
HVAC heater, ventilation, air condition
MET metric
MIC mechanical instrument cluster
MUX multiplexed
ODO odometer
PASS passenger
PCM powertrain control module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Part 1 of 3 > Page 1984
PDC powertrain distribution center
PTC positive temperature coefficient
RKE remote keyless entry
TCM transmission control module
VF vacuum fluorescent display
VTSS
vehicle theft security system
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures
Body Control Module: Symptom Related Diagnostic Procedures
AM/FM Switch Inoperative
SYMPTOM
* AM/FM SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Balance Joystick Inoperative
SYMPTOM
* BALANCE JOYSTICK INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Cassette Error
SYMPTOM
CASSETTE ERROR
POSSIBLE CAUSES
- Cassette Error / Replace radio
CD Eject Switch Inoperative
SYMPTOM
* CD EJECT SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
CD Error
SYMPTOM
CD ERROR
POSSIBLE CAUSES
- Defective radio
Equalizer Inoperative
SYMPTOM
* EQUALIZER INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
External CD Changer (If Equipped)
SYMPTOM
* EXTERNAL CD CHANGER (IF EQUIPPED)
POSSIBLE CAUSES
- Radio/CD cable loose/disconnected
- DIN cable data bus (CAV 1) open
- DIN cable data bus (CAV 3) open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1987
- DIN cable terminals shorted
- DIN signal wires (CAVS 2, 4, and 5) open
- DIN fused B(+) circuit open
- DIN fused ignition switch output circuit open
- DIN ground circuit open
- DIN metal connectors open
- Radio defective
- Radio input control defective
FF/RW Switch Inoperative
SYMPTOM
* FF/RW SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Hour/Minute Switch Inoperative
SYMPTOM
* HOUR/MINUTE SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
No Sound From All Speakers
SYMPTOM
* NO SOUND FROM ALL SPEAKERS
POSSIBLE CAUSES
- Radio 12V output circuit defective, open
- Radio ground circuit defective, open
- Power relay output circuit defective, open
- Radio 12V output circuit shorted to ground
- Radio choke defective
- Speaker power relay defective, open
- Speaker power relay defective, open
- Junction block defective, open circuit
- Defective radio
- Radio choke output circuit defective, open
- Radio output circuits defective
No Sound From One Speaker
SYMPTOM
* NO SOUND FROM ONE SPEAKER
POSSIBLE CAUSES
- Door or quarter speaker (+) circuit defective, open
- Door or quarter speaker (-) circuit defective, open
- Door or quarter speaker (+) circuit open
- Door or quarter speaker (-) circuit open
- Instrument panel or pillar speaker (+) circuit open
- Instrument panel or pillar speaker (-) circuit open
- Door or quarter speaker defective
- Speaker defective, no response
Pause/Play Switch Inoperative
SYMPTOM
* PAUSE/PLAY SWITCH INOPERATIVE
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1988
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Poor Sound Quality All Speakers
SYMPTOM
* POOR SOUND QUALITY ALL SPEAKERS
POSSIBLE CAUSES
- Antenna connector defective
- Antenna connections defective
- Hood ground defective
- Ground circuit defective, open
- Radio connectors not properly connected
- Ignition / alternator system noise
- Radio defective
Poor Sound Quality From One Speaker
SYMPTOM
* POOR SOUND QUALITY FROM ONE SPEAKER
POSSIBLE CAUSES
- Ground circuit open
- Instrument panel - pillar speaker defective
- Radio choke output circuit open
- Speaker (+) and (-) circuits shorted together
- Inoperative speaker defective
PWR Switch Inoperative
SYMPTOM
* PWR SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Radio Error
SYMPTOM
RADIO ERROR
POSSIBLE CAUSES
- Defective radio
Remote Controls Inoperative
SYMPTOM
* REMOTE CONTROLS INOPERATIVE
POSSIBLE CAUSES
- No response, CCD bus failure
- Radio control harness defective, open
- Radio control MUX circuit shorted
- Remote control switch defective
- MUX control clockspring defective
- Radio control ground circuit to BCM open
- Radio control MUX circuit open
- Radio MUX control circuit defective
- Body Control Module defective
Scan Switch Inoperative
SYMPTOM
* SCAN SWITCH INOPERATIVE
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1989
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Seek Switch Inoperative
SYMPTOM
* SEEK SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Set Switch Inoperative
SYMPTOM
* SET SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Shorted Front Channel
SYMPTOM
SHORTED FRONT CHANNEL
POSSIBLE CAUSES
- Left door speaker shorted
- Left front instrument panel speaker shorted
- Right door speaker shorted
- Right front instrument panel speaker shorted
- Right front (-) circuit shorted to ground
- Right front (+) and (-) circuits shorted together
- Right front (+) circuit shorted to ground
- Left front (+) and (-) circuits shorted together
- Left front (+) circuit shorted to ground
- Left front (-) circuit shorted to ground
- Radio output circuits defective
Shorted Left Channel
SYMPTOM
SHORTED LEFT CHANNEL
POSSIBLE CAUSES
- Left door speaker defective, shorted
- Left front instrument panel speaker defective, shorted
- Left quarter speaker shorted
- Left rear (+) and (-) circuits shorted together
- Left rear (+) circuit shorted to ground
- Left rear (-) circuit shorted to ground
- Left rear speaker shorted
- Left front (+) and (-) circuits shorted together
- Left front (+) circuit shorted to ground
- Left front (-) circuit shorted to ground
- Radio output circuits defective
Shorted Rear Channel
SYMPTOM
SHORTED REAR CHANNEL
POSSIBLE CAUSES
- Right rear quarter speaker shorted
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1990
- Left rear (+) and (-) circuits shorted together
- Left rear (+) circuit shorted to ground
- Left rear (-) circuit shorted to ground
- Left rear quarter speaker shorted
- Left rear speaker shorted
- Right rear (+) and (-) circuits shorted together
- Right rear (+) circuit shorted to ground
- Right rear (-) circuit shorted to ground
- Right rear pillar speaker shorted
- Radio output circuits defective
Shorted Right Channel
SYMPTOM
SHORTED RIGHT CHANNEL
POSSIBLE CAUSES
- Right channel speaker shorted
- Right instrument panel speaker defective, shorted
- Right front (+) circuit shorted to ground
- Right front (+) and (-) circuits shorted together
- Right front (-) circuit shorted to ground
- Right pillar speaker shorted
- Right quarter speaker shorted
- Right rear (+) and (-) circuits shorted together
- Right rear (+) circuit shorted to ground
- Right rear (-) circuit shorted to ground
- Radio output circuits defective
Tape Eject Switch Inoperative
SYMPTOM
* TAPE EJECT SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Tune Switch Inoperative
SYMPTOM
* TUNE SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Volume/Time Switch Inoperative
SYMPTOM
* VOL/TIME SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
1-5 Presets Inoperative
SYMPTOM
* 1-5 PRESETS INOPERATIVE
POSSIBLE CAUSES
- Radio function controls inoperative
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1991
Chime Inoperative at All Times
SYMPTOM
* CHIME INOPERATIVE AT ALL TIMES
POSSIBLE CAUSES
- BCM fails chime test
Chime Inoperative With Driver Seat Belt Unfastened
SYMPTOM
* CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED
POSSIBLE CAUSES
- Ground circuit to left seat belt switch connector open
- Left seat belt switch open
- BCM not responding to belt switch
- Body Control Module seat belt switch sense open
- Seat belt switch sense circuit open
Chime Inoperative With Engine Temperature Critical
SYMPTOM
* CHIME INOPERATIVE WITH ENGINE TEMPERATURE CRITICAL
POSSIBLE CAUSES
- BCM - No response to oil pressure
- BCM fails chime test
Chime Inoperative With Exterior Lamps On
SYMPTOM
* CHIME INOPERATIVE WITH EXTERIOR LAMPS ON
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition Switch - key in switch shorted
- BCM - no chime response - head/park lamps ON
- BCM - key in sense shorted default
- BCM - no response to park lamp switch
- Chime inoperative with exterior lamps ON
Chime Inoperative With Key In Ignition & Driver Door Open
SYMPTOM
* CHIME INOPERATIVE WITH KEY IN IGNITION & DRIVER DOOR OPEN
POSSIBLE CAUSES
- Ignition switch ground circuit open
- Key in ignition switch sense circuit open
- Ignition switch - key in switch open
- BCM - no chime to key in ignition
- BCM not responding to key in switch
Chime Inoperative With L or R Turn Signal On For 1 Mile
SYMPTOM
* CHIME INOPERATIVE WITH LEFT OR RIGHT TURN SIGNAL ON FOR 1 MILE
POSSIBLE CAUSES
- Junction block - Left turn signal open
- Junction block - Right turn signal open
- BCM - no response to turn signal
- BCM fails speed test
- Chime - speedometer problem
- Chime inoperative - turn signal on for 1 mile
Chime Inoperative With Low Oil Pressure
SYMPTOM
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1992
* CHIME INOPERATIVE WITH LOW OIL PRESSURE
POSSIBLE CAUSES
- BCM - No response to oil pressure
- BCM fails chime test
Chime Inoperative With the Dome Lamps On
SYMPTOM
* CHIME INOPERATIVE WITH THE DOME LAMPS ON
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition switch - key in switch shorted
- BCM failed - door open & key out default
- BCM - key in switch sense shorted default
Chime Sounds With Driver Door Open & Key Out
SYMPTOM
* CHIME SOUNDS WITH DRIVER DOOR OPEN & KEY OUT
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition switch - key in switch shorted
- BCM - key in switch sense shorted default
- BCM not responding to key out
Chime Sounds With Driver Seat Belt Fastened
SYMPTOM
* CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED
POSSIBLE CAUSES
- Seat belt switch sense circuit shorted to ground
- Left seat belt switch shorted
- BCM - no response to seat belt fastened
- BCM seat belt switch input shorted to ground
Auto Headlamps Will Not Turn Off
SYMPTOM
* AUTO HEADLAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- No response (PCM) - CCD bus failure
- Auto headlamp signal circuit open
- Auto headlamp signal circuit shorted to ground
- Electrochromic mirror defective - sensor stuck ON (default)
- BCM defective - auto headlamp sensor stuck ON
Auto Headlamps Will Not Turn On
SYMPTOM
* AUTO HEADLAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- NO response (BCM) - CCD bus failure
- NO response (PCM) - CCD bus failure
- Auto headlamp signal circuit open
- Electrochromic mirror defective (default)
- BCM defective - auto headlamp sensor
Fog Lamps Will Not Turn Off
SYMPTOM
* FOG LAMPS WILL NOT TURN OFF
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1993
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Fog lamp switched ground circuit shorted to ground
- Headlamp switch defective - foglamp switched ground
Fog Lamps Will Not Turn On
SYMPTOM
* FOG LAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Fog lamp bulbs open
- Fog lamp relay control circuit open
- Fog lamp relay output circuit open
- Fog lamp relay defective, open
- Multifunction dimmer switch defective (open) default
- Fog lamp switched ground circuit open
- BCM defective - Headlamp relay control
- Multifunction switch defective (fog lamp relay control) default
- Headlamp relay control circuit (foglamps) open
Headlamps Will Not Turn Off
SYMPTOM
* HEADLAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch sense circuit shorted to ground
- Headlamp relay control circuit shorted to ground
- Low beam relay control circuit shorted to ground
- Low beam relay control circuit (QUAD) shorted to ground
- Low beam headlamp relay (QUAD) defective, shorted
- Low beam headlamp relay defective (shorted) by default
- PDC defective (low beam headlamp relay connector shorted)
- Headlamp switch defective - switch sense
- BCM defective (headlamp switch sense function) by default
- BCM defective (low beam relay control shorted) by default
Headlamps Will Not Turn On
SYMPTOM
* HEADLAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch ground circuit open
- Both low beam fuses open
- Fused low beam output circuit open (both lamps inoperative)
- Fused low beam output circuit open (one lamp inoperative)
- Headlamp defective (by default)
- Headlamp fuse open
- Headlamp switch sense circuit open
- Headlamps defective (by default)
- Multifunction switch defective (default)
- Headlamp relay control circuit open
- Low beam relay control circuit (Chrysler) open
- Low beam relay control circuit open
- Low beam headlamp relay defective (by default)
- Low beam relay defective - relay control function
- PDC defective - B(+) circuit at low beam fuse terminal
- Power Distribution Center defective (low beam relay CAV A)
- Power Distribution Center defective (low beam relay CAV B)
- Headlamp switch defective (by default)
- BCM defective - headlamp switch sense function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1994
- BCM defective - headlamp switch sense stuck open
- BCM defective - low beam relay control open
Park Lamps Will Not Turn Off
SYMPTOM
* PARK LAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Park lamp relay control circuit shorted to ground
- Park lamp relay output circuit shorted to voltage
- Park lamp switch sense circuit shorted to ground
- Park lamp relay defective - control shorted (by default)
- Headlamp switch defective - shorted
- BCM defective - park lamp switch sense closed (by default)
Park Lamps Will Not Turn On
SYMPTOM
* PARK LAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch ground circuit open
- Fused park lamp output circuit open
- Park lamp bulb defective (by default)
- Park lamp fuse in PDC open
- Both park lamp fuses open
- Park lamp fuse open
- Park lamp relay control circuit open
- Park lamp relay output circuit open
- Park lamp switch sense circuit open
- Park lamp relay defective (control function)
- PDC defective - other B(+) cavity
- PDC defective - park lamp relay connector, fused B(+)
- Headlamp switch defective - park lamps (by default)
- BCM defective - park lamp switch sense stuck open
- BCM defective - park lamp switch sense function
- BCM defective - parklamp control function (by default)
ABS Warning Lamp
SYMPTOM
* ABS WARNING LAMP
POSSIBLE CAUSES
- BCM connector observable defect
- CAB connector observable defect
- Fused ignition switch output circuit open
- ABS warning lamp defective
- ABS warning lamp driver circuit open
- ABS warning lamp driver circuit shorted to ground
- ABS warning lamp flashing
- BCM defective
- CAB defective
Airbag Warning Lamp
SYMPTOM
* AIRBAG WARNING LAMP
POSSIBLE CAUSES
- Airbag warning lamp failure
All Warning Lamps Out
SYMPTOM
* ALL WARNING LAMPS OUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1995
POSSIBLE CAUSES
- Fused B(+) circuit open
- Fused ignition switch output circuit open
- Ground circuit open
- Information Center defective
Engine Temperature Warning Lamp
SYMPTOM
* ENGINE TEMPERATURE WARNING LAMP
POSSIBLE CAUSES
- Engine temperature lamp staying on
- Temperature lamp not working
- Engine temperature lamp/bulb defective
- Fused ignition switch output circuit open
- Defective BCM
- Engine temperature warning lamp driver circuit open
- Temperature warning lamp driver circuit shorted to ground
- Information Center defective
- Body Control Module defect
- Defective Information Center
High Beam Indicator Lamp
SYMPTOM
* HIGH BEAM INDICATOR LAMP
POSSIBLE CAUSES
- Headlamps inoperative
- Fused right highbeam output circuit open
- Ground circuit open
- High beam indicator bulb defective
- Defective Information Center
Low Oil Pressure Warning Lamp
SYMPTOM
* LOW OIL PRESSURE WARNING LAMP
POSSIBLE CAUSES
- Oil pressure low
- Oil warning lamp/bulb defective
- Oil level low
- Defective oil pressure switch
- Oil pressure switch sense circuit shorted to ground
- Oil pressure switch sense circuit open
- Oil pressure switch defective
- BCM defective
- Defective Information Center
Red Brake Warning Lamp
SYMPTOM
* RED BRAKE WARNING LAMP
POSSIBLE CAUSES
- Park brake pedal problem
- Vehicle equipped antilock brakes
- Brake fluid level low
- Red brake warn lamp/bulb defective
- Ground circuit open
- Brake fluid level switch defective
- Defective ignition switch
- Defective park brake switch
- Red brake warning lamp circuit open
- Red brake warning lamp circuit shorted to ground
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1996
- Information Center faulty
- Ignition switch defective
- Red brake warning lamp driver circuit open
- Red brake warning lamp driver circuit faulty
Service Engine Soon Lamp
SYMPTOM
* SERVICE ENGINE SOON LAMP
POSSIBLE CAUSES
- DTC's are present
- Bulb & socket defective
- Service Engine Soon indicator lamp driver circuit open
- Service Engine Soon indicator lamp circuit shorted to ground
- Defective Information Center circuit board
- Powertrain Control Module defective
Turn Signal Indicator Lamp
SYMPTOM
* TURN SIGNAL INDICATOR LAMP
POSSIBLE CAUSES
- Turn signal lamps inoperative
- Ground circuit open
- Left turn signal circuit open
- Right turn signal circuit open
- Turn signal bulbs defective
- Junction Block defective
- BCM defective
- Information Center defective
Vehicle Theft Alarm Indicator
SYMPTOM
* VEHICLE THEFT ALARM INDICATOR
POSSIBLE CAUSES
- Vehicle theft alarm indicator defective
All Gauges Inoperative
SYMPTOM
* ALL GAUGES NOT OPERATING
POSSIBLE CAUSES
- BCM instrument cluster circuit output defective
- Instrument Cluster PC board defective
- DRB shows ignition unlock closed
- No response - CCD bus instrument cluster
- Body computer odometer failure
- RAM test failure
- ROM test failure
Cluster Illumination
SYMPTOM
* CLUSTER ILLUMINATION
POSSIBLE CAUSES
- No response - CCD bus instrument cluster
- Headlamp switch ground circuit defective
- Inoperative lamp defective
- Headlamp switch defective
- Junction block defective
- Dimmer switch signal circuit open
- Dimmer switch signal circuit shorted to ground
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1997
- Instrument panel lamps driver circuit shorted to ground
- Panel lamps driver circuit open
- Park lamps not lighting
- Instrument Cluster circuit board defective
- BCM dimmer switch signal circuit output faulty
- BCM defective
- BCM defective by default
- Body computer odometer failure
- BCM dimmer switch signal circuit defective
- Illumination panel fuse OK
- Inoperative lamp ground circuit
- RAM test failure
- ROM test failure
Cluster Warning Lamps Odometer and PRNDL Display
SYMPTOM
* CLUSTER WARNING LAMPS ODOMETER AND PRNDL DISPLAY
POSSIBLE CAUSES
- Any one lamp/bulb defective
- Washer fluid level switch sense circuit open
- Washer fluid level switch sense ground circuit open
- Washer fluid level switch sense circuit shorted
- Body computer odometer failure DTC
- No response - CCD bus instrument cluster
- Washer fluid level switch defective
- BCM washer fluid switch sense circuit input defective
- All segments fail to light
- Faulty odometer and PRNDL lamp
- Generator lamp failure
- Instrument cluster printed circuit board defective
Gauges Not Returning to Zero With Key Off
SYMPTOM
* GAUGES NOT GOING TO ZERO WHEN KEY IS TURNED OFF
POSSIBLE CAUSES
- Fused B(+) circuit open
- No response - CCD bus instrument cluster
- Instrument Cluster PC board defective
- Body computer odometer failure
- RAM test failure
- ROM test failure
One Gauge Not Operating Properly
SYMPTOM
* ONE GAUGE OPERATING IMPROPERLY
POSSIBLE CAUSES
- DRB reads active on the bus
- DRB reads no vehicle speed sense signal code
- IOD fuse is loose in junction block
- Speedometer calibration out
- Any one lamp/bulb defective
- DRB reading not matching RPM
- Washer fluid level switch sense circuit open
- Washer fluid level switch sense ground circuit open
- Washer fluid level switch sense circuit shorted
- Washer fluid level switch defective
- Gauge pack defective
- Speedometer/Odometer gauge pack defective
- Tachometer calibration out
- Cooling system condition faulty
- DRB reads coolant temperature sensor code
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1998
- DRB reads engine temperature accurately
- BCM instrument cluster circuit output defective
- Body Control Module defective
- Gauge pack defective
- Instrument Cluster printed circuit board defective
- DRB shows ignition unlock closed
- BCM washer fluid level switch sense circuit input defective
- All segments fail to light
- BCM temperature gauge input defective
- Faulty odometer and PRNDL lamp
- Generator lamp failure
- PCM defective
- Pinion factor failure
Trip and Rest Button(S)
SYMPTOM
* TRIP AND RESET BUTTON(S)
POSSIBLE CAUSES
- Trip & reset button(s) defective
Courtesy Lamps Inoperative W/Dome Lamp Switch
SYMPTOM
* COURTESY LAMPS INOPERATIVE W/DOME LAMP SWITCH
POSSIBLE CAUSES
- Courtesy lamp switch sense circuit open
- Headlamp switch defective - courtesy lamp function open
- BCM defective - courtesy lamp switch sense (by default)
- BCM defective - dome lamp switch function
Courtesy Lamps Inoperative With Any Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH ANY DOOR
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Courtesy lamp relay control circuit open
- Switched courtesy lamp relay control circuit open
- Junction block defective - lamp relay fused B(+) (CAV 87) open
- Courtesy lamp relay defective - coil open
- Junction block defective - lamp relay fused B(+) (CAV 30) open
- Junction block defective - lamp relay fused B(+) (CAV 86) Open
- Headlamp switch defective - open
- BCM defective - lamp relay control function (by default)
- BCM defective - driver door ajar switch status
Courtesy Lamps Inoperative With Driver Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH DRIVER DOOR
POSSIBLE CAUSES
- Driver door ajar switch defective, open
- Driver door ajar switch sense circuit open
- Left front door switch ground strap corroded/damaged
- Body Control Module inoperative, open
Courtesy Lamps Inoperative With Left Sliding Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH LEFT SLIDING DOOR
POSSIBLE CAUSES
- Left sliding door ajar switch sense circuit open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 1999
- Left sliding door ajar ground circuit open
- Left sliding door ajar switch defective, open
- BCM defective
Courtesy Lamps Inoperative With Liftgate
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH LIFTGATE
POSSIBLE CAUSES
- Liftgate ground circuit open
- Liftgate ajar switch open - ajar switch disconnected
- Liftgate ajar switch sense circuit open
- BCM defective, open
Courtesy Lamps Inoperative With Passenger Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH PASSENGER DOOR
POSSIBLE CAUSES
- Passenger door ajar switch defective, open
- Passenger door ajar switch sense circuit open
- Right front door switch ground strap corroded/damaged
- Body Control Module inoperative, open
Courtesy Lamps Inoperative With Right Sliding Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH RIGHT SLIDING DOOR
POSSIBLE CAUSES
- Right sliding door ajar switch defective, open
- Right sliding door ajar switch sense circuit open
- Right sliding door ajar ground circuit open
- BCM defective, open
Courtesy Lamps On at All Times
SYMPTOM
* COURTESY LAMPS ON AT ALL TIME
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Courtesy lamp relay output circuit shorted to B(+)
- Courtesy lamp relay control circuit shorted to ground
- Switched courtesy lamp relay control circuit shorted to ground
- Courtesy lamp relay defective - coil shorted
- Headlamp switch shorted
- BCM defective - relay control shorted (by default)
Illuminated Entry Inoperative With Driver Door Key Cylinder
SYMPTOM
* ILLUMINATED ENTRY INOPERATIVE WITH DRIVER DOOR KEY CYLINDER
POSSIBLE CAUSES
- Driver door key switch unlock position stuck
- Driver door key cylinder switch defective
- Driver door key switch sticking
Illuminated Entry Inoperative With RKE Transmitter
SYMPTOM
* ILLUMINATED ENTRY INOPERATIVE WITH RKE TRANSMITTER
POSSIBLE CAUSES
- RKE circuit at BCM defective
- RKE ground circuit open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 2000
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- Defective door lock switch
- Defective unlock switch
- RKE module default replacement
- RKE module defective
CMTC Avg MPH/Fuel Economy Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE OR
WRONG
POSSIBLE CAUSES
- No PCM communications
- TPS inoperative
- VSS signal inoperative
CMTC Elapsed Time Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER ELAPSED TIME INOPERATIVE OR WRONG
POSSIBLE CAUSES
- Defective BCM / Indicator lights
CMTC Fails to Respond to Instrument Cluster Dimming
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER
DIMMING
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer
CMTC Trip Odometer Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER TRIP ODOMETER INOPERATIVE OR WRONG
TEST NOTE
This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER AVG MPH OR
FUEL ECONOMY INOPERATIVE/WRONG.
POSSIBLE CAUSES
- No PCM communications
- TPS inoperative
- VSS signal inoperative
Compass/Mini-Trip Computer Displaying OC
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER DISPLAYING OC
POSSIBLE CAUSES
- Open sensor ground circuit
- Ambient Temperature Sensor defective
- Open Ambient Temperature Sensor signal circuit
- Defective Compass/Mini-Trip Module - sensor ground circuit.
Compass/Mini-Trip Computer Displaying SC
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER DISPLAYING SC
POSSIBLE CAUSES
- Defective Ambient Temperature Sensor
- Ambient Temperature Sensor signal circuit shorted to ground
- Compass/Mini-Trip Module default
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 2001
Compass/Mini-Trip Computer Segments Fail to Light
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SEGMENTS FAIL TO LIGHT
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer - segments fail to light
Compass/Mini-Trip Computer Shows Failed
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SHOWS FAILED
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer - shows failed
Compass/Mini-Trip Computer Switch Inoperative
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER FAILS TO
RESPOND TO INSTRUMENT CLUSTER DIMMING.
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer
Incorrect Ambient Temperature Readings
SYMPTOM
* INCORRECT AMBIENT TEMPERATURE READINGS
POSSIBLE CAUSES
- Open sensor ground - defective CMTM
- Sensor ground circuit partial short to ground
- Defective Ambient Temperature Sensor/Road test
- Ambient Temperature Sensor signal circuit partial short
- Ambient Temperature Sensor signal circuit shorted
- Defective Compass/Mini-Trip Module
- Defective Compass/Mini-Trip Module sensor ground circuit
Add'l All Doors (Exc Drvr w/RKE) Fail Lck/Unlckfrom Any Switch
SYMPTOM
ADDITIONAL ALL DOORS (EXCEPT DRVR W/RKE) FAIL LCK/UNLCK FROM ANY SWITCH
POSSIBLE CAUSES
- Junction block defective
- Door unlock relay output circuit open
- Door unlock relay output circuit resistance low
Additional All Doors (Exc Driver w/RKE) Fail to Unlock
SYMPTOM
ADDITIONAL ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK
POSSIBLE CAUSES
- Fused B(+) circuit voltage too low at junction block
- Door unlock relay control inoperative at BCM
- Door unlock relay defective
- Door unlock relay coil resistance out of tolerance
- Door unlock relay output circuit shorted to ground
Additional All Doors Fail to Lock and Unlock From Any Switch
SYMPTOM
* ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 2002
POSSIBLE CAUSES
- Passenger door switch MUX shorted to battery
- Door lock switch resistance high in unlock position
- Driver door switch MUX circuit shorted to battery
- Liftgate switch MUX shorted to battery
- BCM door lock relay control circuit inoperative
- Liftgate switch MUX at BCM defective
- Door lock relay control ground circuit open
- Door lock relay defective
- Fuse # 26 defective
- Fused B(+) circuit open
- Fused B(+) circuit shorted to ground
- Ground circuit open at door lock relay connector
Additional All Doors Fail to Lock and Unlock From One Switch
SYMPTOM
ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH
POSSIBLE CAUSES
- Door key cylinder switch connector circuit ground circuit open
- Door key cylinder switch defective
- Liftgate key cylinder switch defective
- Liftgate switch MUX shorted to battery
- Door switch MUX circuit to BCM open
- Driver door switch MUX circuit open at BCM connector
- Liftgate switch MUX circuit open at BCM connector
- Liftgate switch MUX circuit to BCM open
- Passenger door switch MUX circuit open at BCM connector
- Passenger door switch MUX circuit to BCM open
- Door lock switch connector ground circuit open
- Door lock switch defective
- Door lock switch MUX circuit open
- Door locks inoperative from key cylinder switch
- Door switch MUX circuit shorted to battery
Additional All Doors Failing to Lock From Any Switch
SYMPTOM
ADDITIONAL ALL DOORS FAILING TO LOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Fused B(+) circuit voltage too low at junction block
- Door lock relay control circuit from BCM fails
- Key - in ignition switch circuit to BCM defective
- Door lock relay does not operate
- Door lock relay coil resistance out of tolerance
- Door lock relay output shorted to ground
- Ignition switch defective
- Key - in ignition switch sense circuit shorted to ground
Additional Driver Door (w/RKE) Failing to Unlock From Any SW
SYMPTOM
ADDITIONAL DRIVER DOOR (W/RKE)FAILING TO UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Driver door unlock relay coil resistance out of tolerance
- Driver door unlock relay defective
- Driver door unlock relay output circuit shorted to ground
- Voltage too low at junction block fused B(+) circuit
Additional One Door Fails to Lock and Unlock From Any Switch
SYMPTOM
ADDITIONAL ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 2003
POSSIBLE CAUSES
- RKE equipped door lock fails to lock & unlock
- Door lock motor defective
- Driver unlock relay ground open in junction block
- Door lock relay output circuit open
- Door unlock relay output circuit open
- Driver door unlock relay open
All Doors (Exc Driver w/RKE) Fail Lock/Unlock From Any Switch
SYMPTOM
* ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors (Exc Driver w/RKE) Fail to Unlock
SYMPTOM
* ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK
POSSIBLE CAUSES
- RKE circuit at BCM defective
- RKE ground circuit open
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- Defective door lock switch
- Defective door unlock switch
- RKE module default replacement
- RKE module defective
All Doors Fail to Lock and Unlock From Any Switch
SYMPTOM
* ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Link to body communication bus inoperative
- Defective door lock switch
- Defective unlock switch
All Doors Fail to Lock and Unlock From One Switch
SYMPTOM
* ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors Failing to Lock From Any Switch
SYMPTOM
* ALL DOORS FAILING TO LOCK FROM ANY SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 2004
- Defective unlock switch
All Doors Failing to Lock From One Switch
SYMPTOM
* ALL DOORS FAILING TO LOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors Failing to Unlock From One Switch
SYMPTOM
* ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
Automatic Door Locks Do Not Lock Over 15 MPH
SYMPTOM
* AUTOMATIC DOOR LOCKS DO NOT LOCK OVER 15 MPH
POSSIBLE CAUSES
- Link to body communication bus inoperative
- TPS malfunction causes door lock problem
- VSS malfunction causes door lock problem
- Auto door lock not enabled
Doors Lock With Key In Ignition and Left Door Open
SYMPTOM
* DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN
POSSIBLE CAUSES
- Link to body communication bus inoperative
- BCM defective
- BCM sends wrong key - in ignition status
- BCM a connector terminals damaged
- Ignition switch open
- Key - in ignition switch ground circuit open
- Key - in ignition switch sense circuit open
Driver Door (w/RKE) Failing to Unlock From Any Switch
SYMPTOM
* DRIVER DOOR (W/RKE) FAILING TO UNLOCK FROM ANY SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
One Door Fails to Lock and Unlock From Any Switch
SYMPTOM
* ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 2005
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
Remote Keyless Entry Problem
SYMPTOM
* RKE PROBLEM
POSSIBLE CAUSES
- Link to body communication bus inoperative
- RKE circuit at BCM defective
- RKE ground circuit open
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- RKE module default replacement
- RKE module defective
Front Wiper Operating Constantly W/Switch In Off Position
SYMPTOM
* FRONT WIPER OPERATING CONSTANTLY W/SWITCH IN OFF POSITION
POSSIBLE CAUSES
- Front wiper ON/OFF relay control circuit shorted to ground
- Defective wiper ON relay/substitute relay
- Defective multifunction switch/voltage
- High/Low wiper relay HI speed output circuit shorted to voltage
- High/Low wiper relay LO speed output circuit shorted to voltage
- Defective BCM - 100 ohms default
Front Wipers Not Parking In Off Position
SYMPTOM
* FRONT WIPERS NOT PARKING IN OFF POSITION
TEST NOTE
This symptom is diagnosed using the test FRONT WIPER PARK SWITCH CIRCUIT OPEN
POSSIBLE CAUSES
- Wiper park switch toggle closed/open
- Open wiper park switch sense circuit
- Defective BCM - wiper park switch
- Defective wiper motor/wiper park switch
Front Wipers Not Working at All
SYMPTOM
* FRONT WIPERS NOT WORKING AT ALL
POSSIBLE CAUSES
- Open wiper on relay control circuit - BCM/wiper relay
- Defective wiper ON relay - BCM/ground
- Front wiper switch MUX circuit shorted to ground
- Open front wiper switch MUX circuit between switch and BCM
- Defective High/Low wiper relay - relay connector
- Defective multifunction switch/front wiper switch
- High/Low wiper relay HI speed output circuit shorted to ground
- High/Low wiper relay LO speed output circuit shorted to ground
- Open ground circuit/lights
- Open High/Low relay LO speed output circuit between High/Low relay and wiper motor
- Open fused ignition switch output circuit/multifunction switch
- Defective Power Distribution Center - relay connector
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 2006
- Defective Power Distribution Center - front wiper relay
- Defective Power Distribution Center - wiper ON relay
- Defective Power Distribution Center - wiper relay
- Defective Power Distribution Center - H/L relay
- Defective Power Distribution Center - B(+) circuit.
- Defective wiper motor/harness
- Defective BCM/wiper relay
- Defective BCM/front wiper MUX
- Defective BCM/sensors
- Defective wiper motor ground circuit.
Front Wipers Not Working In High Speed Mode
SYMPTOM FRONT WIPERS NOT WORKING IN HIGH SPEED MODE
POSSIBLE CAUSES
- Open HI/LO wiper relay control circuit
- Defective HI/LO wiper RELAY - Wiper switch
- Open wiper HI/LO relay HI speed output circuit
- Defective multi - FUNCT switch/ ground circuit
- Defective power DIST CNTR-H/L WPR RLY
- Defective wiper Motor/HI speed output circuit
- Open ground circuit/Multi - Function switch
Front Wipers Not Working In Intermittent Mode
SYMPTOM
* FRONT WIPERS NOT WORKING IN INTERMITTENT MODE
POSSIBLE CAUSES
- Defective multifunction switch/positions
- Defective BCM/wiper positions
- Defective multifunction switch/Default
Front Wipers Not Working In Low Speed Mode
SYMPTOM
* FRONT WIPERS NOT WORKING IN LOW SPEED MODE
POSSIBLE CAUSES
- High/Low wiper relay control circuit shorted to ground
- Defective High/Low wiper relay - fused ignition switch
- Open High/Low wiper relay - LO speed output circuit
- Defective wiper motor/LO speed output circuit
Rear Washer Motor Inoperative
SYMPTOM
* REAR WASHER MOTOR INOPERATIVE
POSSIBLE CAUSES
- Open rear washer motor control circuit
- Defective rear washer motor/jumper
- Open fused ignition switch output circuit/voltage
- Defective HVAC Control Module / 3.8 volts
- Defective BCM - washer motor operate
Rear Wiper Not Parking In the Off Position
SYMPTOM
* REAR WIPER NOT PARKING IN THE OFF POSITION
POSSIBLE CAUSES
- Rear wiper motor control circuit shorted to battery
- Defective HVAC Control Module/switch indicator lights
- Defective wiper motor/wiper motor connector
- Defective BCM/rear wiper motor - default
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 2007
- Defective BCM/washer motor run
- Defective BCM/cycle on default
- Defective BCM/rear wiper switch voltage
- Defective rear wiper motor/test light
Rear Wiper Not Working at All
SYMPTOM
* REAR WIPER NOT WORKING AT ALL
POSSIBLE CAUSES
- Open rear wiper motor control circuit
- Open rear wiper switch MUX circuit
- Open ground circuit/rear wiper motor
- Open fused ignition switch output circuit/fuse # 6
- Open fused ignition switch output circuit/fuse # 8
- Shorted fused ignition switch output circuit/fuse # 6
- Defective rear wiper motor/motor control
- Defective HVAC Control Module/default
- Defective HVAC Control Module/rear wiper switch MUX
- Defective BCM/rear wiper switch MUX
- Defective BCM/rear wiper motor
- Defective HVAC Control Module/21-Way connector
Rear Wiper Not Working In the Intermittent Mode
SYMPTOM
* REAR WIPER NOT WORKING IN THE INTERMITTENT MODE
POSSIBLE CAUSES
- Defective rear wiper motor/intermittent switch
- Defective HVAC Control Module/indicator light
- Defective HVAC Control Module/rear wiper switch
- Defective BCM/test light default
Rear Wiper/Wash Working Continuously
SYMPTOM
* REAR WIPER/WASH WORKING CONTINUOUSLY
POSSIBLE CAUSES
- Rear wiper motor control circuit shorted to battery
- Defective wiper motor/wiper motor connector
- Defective BCM/rear wiper motor - default
- Defective BCM/washer motor run
- Defective BCM/rear wiper switch voltage
Wiper/Wash Function Not Working Properly
SYMPTOM
* WIPER/WASH FUNCTION NOT WORKING PROPERLY
POSSIBLE CAUSES
- Defective washer motor/washer pump control
- Operate wipers
- Open washer pump control circuit
- Defective multifunction switch/washer pump control
- Open fused ignition switch output circuit
- Defective junction block/BCM
- Defective junction block/block connector
- Defective BCM/junction block
- Defective BCM/stalk switch
- Fused ignition switch output circuit shorted to ground
- Open washer pump control circuit/multifunction switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Symptom Related Diagnostic Procedures > Page 2008
Body Control Module: Component Tests and General Diagnostics
Six-Step Troubleshooting Procedure
Diagnosis of the body system is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
Road Testing A Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE
REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN
WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE
IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB.
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Body Control Module: Scan Tool Testing and Procedures
Under normal operation, the DRB will display one of only two error messages: - User-Requested
WARM Boot or User-Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the MDS
Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error
message display:
ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD
Boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRB III (R) Does Not Power up (Blank Screen) If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data
link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A.
DRB Scan Tool
Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to
compensate for this condition
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Body Control Module: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove lower steering column cover and
knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control
Module (BCM)
Body Control Module - Location
4. Remove bolts holding Junction Block to dash panel mounting bracket. 5. Remove Junction Block
from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide
Body Control Module downward to disengage guide studs on Junction Block from channels on
BCM mounting bracket. 8. Remove Body Control Module from Junction Block.
INSTALLATION
For installation, reverse the above procedures.
REMOVAL AND INSTALLATION
Refer to Instrument Panel and Systems, Body Control Module Replacement.
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Body Control Module: Tools and Equipment
DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires
ohmmeter voltmeter oil pressure gauge (0-300 psi) test light
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Powertrain Control Module: Locations
Power Distribution Center & Powertrain Control Module (PCM)
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Powertrain Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Powertrain Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Powertrain Control Module: Connector Views
Powertrain Control Module C1
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Powertrain Control Module C2
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Powertrain Control Module: Description and Operation
OPERATION
Powertrain Control Module
The ignition system is regulated by the Powertrain Control Module (PCM). The PCM supplies
battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM also controls
ground circuit for the ignition coil. By switching the ground path for the coil on and off, the PCM
adjusts ignition timing to meet changing engine operating conditions.
During the crank-start period the PCM advances ignition timing a set amount. During engine
operation, the amount of spark advance provided by the PCM is determined by the following input
factors: available manifold vacuum
- barometric pressure
- engine coolant temperature
- engine RPM
- throttle position
The PCM also regulates the fuel injection system. Refer to the Fuel Injection.
The speed control electronic control circuitry is integrated into the Powertrain Control Module
(PCM). The PCM is located in the engine compartment. The PCM speed control functions are
monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the
PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a
DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be
replaced if faulty.
USE THE DRB SCAN TOOL TO REPROGRAM THE NEW PCM WITH THE VEHICLES
ORIGINAL IDENTIFICATION NUMBER (OIN) AND THE VEHICLES ORIGINAL MILEAGE. IF
THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
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Powertrain Control Module: Service and Repair
REMOVAL
1. Disconnect both cables from battery, negative cable first.
NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after
disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection
Power Distribution Center Retaining Screws
2. Remove 2 screws holding Power Distribution Center (PDC) to bracket.
Battery Heat Shield
3. Remove heat shield from battery.
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Battery Clamp
4. Remove nut and clamp holding battery to battery tray. 5. Remove battery from vehicle.
PDC Rear Bracket
6. Rotate PDC toward center of vehicle to remove from rear bracket. 7. Pull PDC rearward to
remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM).
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PCM 40-way Connectors
8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM. Remove both
way connectors.
PCM Removal/Installation
9. Remove 3 screws holding PCM to fender.
10. Remove PCM from vehicle.
INSTALLATION
1. Connect 2 40-Way electrical connectors to PCM. 2. Install PCM. Tighten mounting screws. 3.
Install PDC bracket. 4. Install battery.
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Automatic Shut Down (ASD) Relay: Locations
Battery Negative Cable
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Power Distribution Center -- Sheet 8w-10-2
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Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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> Component Information > Diagrams > Diagram Information and Instructions > Page 2065
Automatic Shut Down (ASD) Relay: Connector Views
Power Distribution Center
Automatic Shut Down Relay
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Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
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> Component Information > Diagrams > Page 2066
Automatic Shut Down (ASD) Relay: Description and Operation
Power Distribution Center
DESCRIPTION
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and
fuses in the PDC.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02
Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM
monitors the crankshaft position sensor and camshaft position sensor signals to determine engine
speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor
and camshaft position sensor signals when the ignition switch is in the Run position, it will
de-energize the ASD relay.
AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT
OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt
signal at this input indicates to the PCM that the ASD has been activated. This input is used only to
sense that the ASD relay is energized.
When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC).
AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT
The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic
ignition coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and
contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss
bar in the PDC and the relay. The fuse is located in the PDC.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2
Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the
On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position
sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not
receive the crankshaft position sensor and camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the ASD relay.
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> Component Information > Diagrams > Page 2067
Power Distribution Center
The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies
the relays and fuses in the PDC.
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> Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
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> Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2070
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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> Component Information > Testing and Inspection > Page 2071
Automatic Shut Down (ASD) Relay: Service and Repair
The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover
has a label showing relay and fuse location.
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Fuel Pump Relay: Locations
Battery Negative Cable
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Power Distribution Center -- Sheet 8w-10-2
The fuel pump relay is located in the PDC.
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Fuel Pump Relay: Diagrams
Power Distribution Center
Fuel Pump Relay
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Fuel Pump Relay: Description and Operation
FUEL PUMP RELAY-PCM OUTPUT
The fuel pump relay supplies battery voltage to the fuel pump. The fuel pump relay power circuit
contains a 9 amp fuse. The fuse is located in the PDC.
The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the
relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position.
When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft
position sensor does not detect engine rotation, the PCM de-energizes the relay after
approximately one second.
The fuel pump relay is located in the PDC. A label affixed to the underside of the PDC cover
identifies the relays and fuses in the PDC.
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Fuel Pump Relay: Testing and Inspection
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
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terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Component Information > Locations > Page 2084
Power Distribution Center -- Sheet 8w-10-2
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Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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Component Information > Diagrams > Diagram Information and Instructions > Page 2087
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Component Information > Diagrams > Diagram Information and Instructions > Page 2088
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Component Information > Diagrams > Diagram Information and Instructions > Page 2089
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Component Information > Diagrams > Diagram Information and Instructions > Page 2090
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Component Information > Diagrams > Diagram Information and Instructions > Page 2091
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Component Information > Diagrams > Diagram Information and Instructions > Page 2092
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Component Information > Diagrams > Diagram Information and Instructions > Page 2094
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Component Information > Diagrams > Diagram Information and Instructions > Page 2095
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Component Information > Diagrams > Diagram Information and Instructions > Page 2098
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Component Information > Diagrams > Diagram Information and Instructions > Page 2100
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Component Information > Diagrams > Diagram Information and Instructions > Page 2101
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Component Information > Diagrams > Diagram Information and Instructions > Page 2102
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 2104
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Component Information > Diagrams > Diagram Information and Instructions > Page 2105
Automatic Shut Down (ASD) Relay: Connector Views
Power Distribution Center
Automatic Shut Down Relay
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Component Information > Diagrams > Page 2106
Automatic Shut Down (ASD) Relay: Description and Operation
Power Distribution Center
DESCRIPTION
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and
fuses in the PDC.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02
Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM
monitors the crankshaft position sensor and camshaft position sensor signals to determine engine
speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor
and camshaft position sensor signals when the ignition switch is in the Run position, it will
de-energize the ASD relay.
AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT
OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt
signal at this input indicates to the PCM that the ASD has been activated. This input is used only to
sense that the ASD relay is energized.
When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC).
AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT
The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic
ignition coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and
contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss
bar in the PDC and the relay. The fuse is located in the PDC.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2
Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the
On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position
sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not
receive the crankshaft position sensor and camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the ASD relay.
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Component Information > Diagrams > Page 2107
Power Distribution Center
The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies
the relays and fuses in the PDC.
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Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
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7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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Component Information > Testing and Inspection > Page 2111
Automatic Shut Down (ASD) Relay: Service and Repair
The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover
has a label showing relay and fuse location.
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Operation
Battery Temperature Sensor: Description and Operation
OPERATION
The temperature sensor, in the PCM, is used to determine the battery temperature. This
temperature data, along with data from monitored line voltage, is used by the PCM to vary the
battery charging rate. System voltage will be higher at colder temperatures and is gradually
reduced at warmer temperatures.
The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II
monitors are either enabled or disabled depending upon the battery temperature sensor input
(example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F.
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Camshaft Position Sensor: Specifications
Camshaft Position Sensor ...................................................................................................................
................................................... 14 Nm (125 in. lbs.)
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Camshaft Position Sensor: Description and Operation
Camshaft Position Sensor Location
DESCRIPTION
The camshaft position sensor is mounted in the front of the timing case cover.
Camshaft Position Sensor
Camshaft Sprocket
OPERATION
The camshaft position sensor provides cylinder identification to the Powertrain Control Module
(PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass
underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the
pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each
group of camshaft pulses.
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When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Ignition Coil Pack
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder
the flat spot and notches identify, they do not indicate TDC position.
CAMSHAFT POSITION SENSOR-PCM INPUT
The PCM determines fuel injection synchronization and cylinder identification from inputs provided
by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM
determines crankshaft position.
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it.
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft
pulses.
The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of
the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel
Injection-Service Procedures.
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Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
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Camshaft Position Sensor: Service and Repair
REMOVAL
Camshaft Position Sensor
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector.
Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt.
Camshaft Sensor Removal/Installation
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3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the
sensor lead. There is an O-ring on the sensor case. The O-ring may make removal
difficult. A light tap to top of sensor prior to removal may reduce force needed for removal.
INSTALLATION
Camshaft Position Sensor And Spacer
If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If
the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is
positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring
prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor
down until contact is made with the camshaft gear. While holding the sensor in this position, install
and tighten the retaining bolt 14
Nm (125 in. lbs.) torque.
4. Connect camshaft position sensor electrical connector to harness connector.
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Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Temperature Sensor 7 Nm
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Coolant Temperature Sensor/Switch (For Computer): Locations
Engine Coolant Temperature Sensor
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Coolant Temperature Sensor/Switch (For Computer): Service Precautions
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT
TEMPERATURE (ECT) SENSOR.
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Coolant Temperature Sensor/Switch (For Computer): Description and Operation
ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT
The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40°
F to 265° F).
The engine coolant temperature sensor provides an input voltage to the PCM. As coolant
temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM.
When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The engine coolant sensor is also used for cooling fan control.
Engine Coolant Temperature Sensor
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
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Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Engine Coolant Temperature Sensor
1. With the key off, disconnect wire harness connector from coolant temperature sensor.
Engine Coolant Temperature Sensor
2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter
should read as follows:
a. ECT STET at normal operating temperature around 200°F should read approximately 700 to
1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately
7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater
than 1 ohm, repair the wire harness as necessary.
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Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT
TEMPERATURE SENSOR.
REMOVAL
1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant
sensor electrical connector. 3. Remove coolant sensor.
INSTALLATION
1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector
to sensor. 3. Fill cooling system.
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Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
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Page 2139
Crankshaft Position Sensor Location
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Page 2141
Crankshaft Position Sensor: Description and Operation
DESCRIPTION
Crankshaft Position Sensor Location
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing. The bottom of the sensor is positioned next to the drive plate.
OPERATION
Crankshaft Position Sensor
Timing Slots
The crankshaft position sensor detects slots cut into the transmission driveplate extension. There
are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the
position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last
slot,
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Page 2142
it determines crankshaft position (which piston will next be at TDC) from the camshaft position
sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°,
and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
CRANKSHAFT POSITION SENSOR-PCM INPUT
The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3
sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of
the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position
(which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM
one engine revolution to determine crankshaft position.
The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing
and presence of misfire. Once crankshaft position has been determined, the PCM begins
energizing the injectors in sequence.
The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor.
The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of
sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft
position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures.
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Page 2143
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
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Page 2144
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Raise and support vehicle.
Crankshaft Position Sensor Connector
2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3.
Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out
of the trans axle housing.
INSTALLATION
Crankshaft Position Sensor And Spacer
NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the face of the new sensor.
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
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Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
Fuel Level Sensor: Locations
The level sensor is attached to the side of the fuel pump module.
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Fuel Level Sensor: Description and Operation
DESCRIPTION
The level sensor is attached to the side of the fuel pump module. The level sensor consists of a
float, an arm, and a variable resistor.
OPERATION
As the fuel level increases, the float and arm move up. This decreases the sending unit resistance,
causing the fuel gauge on the instrument panel to read full.
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Fuel Level Sensor: Testing and Inspection
This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit.
Level Sensor Diagnosis
The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the fuel level changes. To test the level sensor,
connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump
module connector. Move the float lever to the positions shown in the resistance chart. Record the
resistance at each point. Replace the level sensor if the resistance is not within specifications.
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Fuel Level Sensor: Service and Repair
REMOVAL
Remove fuel pump module. Refer to Fuel Pump Module.
Fuel Pump/Level Sensor Electrical Connector
1. Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of
the fuel pump module electrical connector.
NOTE: The pump module harness on TOP of flange is not serviceable or removable.
Wire Terminal Locking Wedge
2. Pull off blue locking wedge.
Wire Terminal Locking Finger
3. Using a small screwdriver lift locking finger away from terminal and push terminal out of
connector.
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Removing Wires From Connector
4. Push level sensor signal and ground terminals out of the connector.
Loosening Level Sensor
5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing.
Push level sensor down slightly.
Level Sensor Removal/Installation
6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of
installation channel in module.
INSTALLATION
1. Insert level sensor wires into bottom of opening in module.
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Groove In Back Side Of Level Sensor
2. Wrap wires into groove in back of level sensor.
Installation Channel
3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into
place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector.
Push the wires up through the connector and then pull them down until they lock in place. Ensure
signal and
ground wires are installed in the correct position.
5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module
electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module.
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Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2156
Knock Sensor
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2157
Knock Sensor: Description and Operation
Knock Sensor
KNOCK SENSOR-PCM INPUT
The knock sensor is only on these engines.
The knock sensor threads into the side of the cylinder block in front of the starter. When the knock
sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response,
the PCM retards ignition timing for all cylinders by a scheduled amount.
Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM.
As the intensity of the engine knock vibration increases, the knock sensor output voltage also
increases.
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Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: ignition timing,
cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude
increases with the increase of engine knock. The knock sensor can be tested with a digital
voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to
approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set.
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Knock Sensor: Service and Repair
Knock Sensor
The knock sensor threads into the side of the cylinder block in front of the starter.
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening
effects knock sensor performance, possibly
causing improper spark control.
2. Attach electrical connector to knock sensor.
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Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
Sensor Tightening Torque 35 in.lb
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> Page 2163
MAP Sensor
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> Page 2165
Manifold Pressure/Vacuum Sensor: Description and Operation
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT
The PCM supplies 5 volts to the MAP sensor. The MAP sensor converts intake manifold pressure
into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP
sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage
increases proportionately.
During cranking, before the engine starts running, the PCM determines atmospheric air pressure
from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold
pressure from the MAP sensor voltage.
Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and
the air/fuel mixture.
MAP Sensor
MAP Sensor
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MAP Sensor
The MAP sensor mounts to the intake manifold near the throttle body inlet to the manifold. The
sensor connects electrically to the PCM.
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Manifold Pressure/Vacuum Sensor: Testing and Inspection
To perform a complete test of the MAP sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following:
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
MAP Sensor Connector
1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3.
With the ignition switch ON and the engine not
running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot,
neutral idle speed condition. If OK, go to next step. If not OK, go to step 3.
2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness
condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1
and PCM terminal 43. If OK, go to next step. If not OK, repair as required. 4. Test MAP sensor
supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should
be approximately 5 volts (±
0.5V). Five volts ± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. If
not OK, repair or replace the wire harness as required.
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Manifold Pressure/Vacuum Sensor: Service and Repair
Map Absolute Pressure Sensor
REMOVAL
1. Disconnect electrical connector from MAP sensor. 2. Remove two screws holding sensor to the
intake manifold.
INSTALLATION
1. Reverse the above procedure for installation.
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Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications
Oxygen Sensor: Specifications
Upstream and Downstream Oxygen Sensor 27 Nm
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Bank Locations
Oxygen Sensor: Locations Oxygen Sensor Bank Locations
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
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Bank Locations > Page 2174
Oxygen Sensor: Locations Oxygen Sensor(s)
Heated Oxygen Sensor
Downstream Heated Oxygen Sensor
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Oxygen Sensor: Diagrams
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Oxygen Sensor: Service Precautions
WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN
SERVICING THE OXYGEN SENSOR
.
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Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
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Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (O2S SENSOR)-PCM INPUT
The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas
in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel
mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel
mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to
electrical voltage, the sensors act as a rich-lean switch.
The oxygen sensors are equipped with a heating element that keeps the sensors at proper
operating temperature during all operating modes. Maintaining correct sensor temperature at all
times allows the system to enter into closed loop operation sooner. Also, it allows the system to
remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM
monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly.
During Open Loop operation the PCM ignores the 02 sensor input. The PCM adjusts injector pulse
width based on preprogrammed (fixed) values and inputs from other sensors.
The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and
downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element.
The heating elements reduce the time required for the sensors to reach operating temperature.
UPSTREAM HEATED OXYGEN SENSOR
Heated Oxygen Sensor
Heated Oxygen Sensor
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Heated Oxygen Sensor
The upstream O2S is located in the exhaust manifold and provides an input voltage to the PCM.
The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to
fine tune the air/fuel ratio by adjusting injector pulse width.
DOWNSTREAM HEATED OXYGEN SENSOR
Downstream Heated Oxygen Sensor
The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic
convertor. The downstream heated oxygen sensor input is used to detect catalytic convertor
deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match
the upstream sensor input except for a slight time delay. By comparing the downstream heated
oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor
efficiency.
When the catalytic converter efficiency drops below emission standards, the PCM stores a
diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information,
refer to Emission Control Systems.
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Oxygen Sensor: Testing and Inspection
Use an ohmmeter to test the heating element of the oxygen sensors. Disconnect the electrical
connector from each oxygen sensor. The white wires in the sensor connector are the power and
ground circuits for the heater. Connect the ohmmeter test leads to terminals of the white wires in
the heated oxygen sensor connector. Replace the heated oxygen sensor if the resistance is not
between 4 and 7 ohms.
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Downstream Oxygen Sensor Replacement
Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement
REMOVAL
1. Raise and support vehicle.
WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN
SERVICING THE OXYGEN SENSOR.
Oxygen Sensor Grommet Cover
2. Remove grommet cover to expose connector.
Oxygen Sensor Connector Locking Tab
3. Push locking tab back and unplug oxygen sensor electrical connector.
Oxygen Sensor Removal/Installation
4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 5. When the sensor is
removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using
original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
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Downstream Oxygen Sensor Replacement > Page 2183
INSTALLATION
1. Reverse removal procedure to install a new sensor.
New sensors are packaged with compound on the threads and no additional compound is required.
The sensor must be tightened to 27 Nm (20 ft. lbs.) torque.
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Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement
Upstream Heated Oxygen Sensor
The oxygen sensor is installed in the exhaust manifold .
CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector.
WARNING: THE EXHAUST MANIFOLD AND CATALYTIC CONVERTER MAY BE EXTREMELY
HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR.
REMOVAL
1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such
as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust
manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
New sensors are packaged with compound on the threads and no additional compound is required.
The sensor must be tightened to 27 Nm (20 ft. lbs.) torque.
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Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications
Throttle Position Sensor: Specifications
Throttle Position Sensor Screw 2 Nm
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2188
Throttle Position Sensor
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2189
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2190
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
THROTTLE POSITION SENSOR (TPS)-PCM INPUT
The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a
variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade
position. As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from
approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with
inputs from other sensors, the PCM uses the TPS input to determine current engine operating
conditions and adjust fuel injector pulse width and ignition timing.
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2191
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to
the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The
center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply
and the remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS
output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output
voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase
as the throttle plate moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM connections before replacing the TPS.
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2192
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws.
Servicing Throttle Position Sensor
4. Lift throttle position sensor off throttle shaft.
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
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Technical Service Bulletins > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
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The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
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NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
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Transmission Range Sensor
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Connector Pin Identification
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Technical Service Bulletins > Page 2201
Transmission Position Switch/Sensor: Description and Operation
Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical
TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT
The park/neutral switch is located on the transaxle housing.
If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral.
This input is used to determine idle speed (varying with gear selection) and ignition timing advance.
The park neutral switch is sometimes referred to as the neutral safety switch.
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Transmission Position Switch/Sensor: Service and Repair
The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
Fig. 20
3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission
range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8.
Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
Fig. 21
11. Place valve body on workbench (Fig. 21).
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Fig. 22
12. Remove TRS retaining screw (Fig. 22).
Fig. 23
13. Remove manual shaft seal (Fig. 23).
Fig. 24
14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24).
INSTALLATION
1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.)
Reseal transaxle oil pan using RTV.
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Vehicle Speed Sensor: Locations
Fig. 26
Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the
PCM. The output speed sensor is located on the side of
the transaxle.
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Vehicle Speed Sensor: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Vehicle Speed Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Information and Instructions > Page 2225
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Vehicle Speed Sensor: Description and Operation
Description
The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC
signals as rotation occurs. They are threaded into the transaxle case and are considered primary
inputs to the Trans- mission Control Module (TCM).
OPERATION
The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of
the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The
TCM interprets this information as input shaft rpm.
The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by
rotation of the rear planetary carrier park pawl lugs. The TCM interprets this information as output
shaft rpm.
The TCM compares the input and output speed signals to determine the following:
^ Transmission gear ratio
^ Speed ratio error detection
^ CVI calculation
The TCM also compares the input speed signal and the engine speed signal to determine the
following:
^ Torque converter clutch slippage
^ Torque converter element speed ratio
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Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications
Throttle Position Sensor: Specifications
Throttle Position Sensor Screw 2 Nm
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2232
Throttle Position Sensor
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2234
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
THROTTLE POSITION SENSOR (TPS)-PCM INPUT
The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a
variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade
position. As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from
approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with
inputs from other sensors, the PCM uses the TPS input to determine current engine operating
conditions and adjust fuel injector pulse width and ignition timing.
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2235
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to
the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The
center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply
and the remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS
output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output
voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase
as the throttle plate moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM connections before replacing the TPS.
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2236
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws.
Servicing Throttle Position Sensor
4. Lift throttle position sensor off throttle shaft.
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
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Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor ...................................................................................................................
................................................... 14 Nm (125 in. lbs.)
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Camshaft Position Sensor: Description and Operation
Camshaft Position Sensor Location
DESCRIPTION
The camshaft position sensor is mounted in the front of the timing case cover.
Camshaft Position Sensor
Camshaft Sprocket
OPERATION
The camshaft position sensor provides cylinder identification to the Powertrain Control Module
(PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass
underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the
pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each
group of camshaft pulses.
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When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Ignition Coil Pack
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder
the flat spot and notches identify, they do not indicate TDC position.
CAMSHAFT POSITION SENSOR-PCM INPUT
The PCM determines fuel injection synchronization and cylinder identification from inputs provided
by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM
determines crankshaft position.
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it.
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft
pulses.
The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of
the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel
Injection-Service Procedures.
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Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
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Camshaft Position Sensor: Service and Repair
REMOVAL
Camshaft Position Sensor
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector.
Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt.
Camshaft Sensor Removal/Installation
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3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the
sensor lead. There is an O-ring on the sensor case. The O-ring may make removal
difficult. A light tap to top of sensor prior to removal may reduce force needed for removal.
INSTALLATION
Camshaft Position Sensor And Spacer
If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If
the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is
positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring
prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor
down until contact is made with the camshaft gear. While holding the sensor in this position, install
and tighten the retaining bolt 14
Nm (125 in. lbs.) torque.
4. Connect camshaft position sensor electrical connector to harness connector.
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
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Crankshaft Position Sensor Location
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Crankshaft Position Sensor: Description and Operation
DESCRIPTION
Crankshaft Position Sensor Location
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing. The bottom of the sensor is positioned next to the drive plate.
OPERATION
Crankshaft Position Sensor
Timing Slots
The crankshaft position sensor detects slots cut into the transmission driveplate extension. There
are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the
position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last
slot,
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it determines crankshaft position (which piston will next be at TDC) from the camshaft position
sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°,
and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
CRANKSHAFT POSITION SENSOR-PCM INPUT
The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3
sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of
the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position
(which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM
one engine revolution to determine crankshaft position.
The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing
and presence of misfire. Once crankshaft position has been determined, the PCM begins
energizing the injectors in sequence.
The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor.
The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of
sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft
position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures.
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Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
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Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Raise and support vehicle.
Crankshaft Position Sensor Connector
2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3.
Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out
of the trans axle housing.
INSTALLATION
Crankshaft Position Sensor And Spacer
NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the face of the new sensor.
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
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Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or
Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
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Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or
Cannot Be Removed > Page 2266
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not
Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not
Turn And/Or Cannot Be Removed > Page 2272
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 2273
Ignition Switch Lock Cylinder: Description and Operation
DESCRIPTION
The lock cylinder is inserted in the end of the housing opposite the ignition switch.
OPERATION
Ignition Lock Cylinder Detents
The ignition key rotates the cylinder to 5 different detents: Accessory
- Off (lock)
- Unlock
- On/Run
- Start
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 2274
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 2275
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2279
Knock Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2280
Knock Sensor: Description and Operation
Knock Sensor
KNOCK SENSOR-PCM INPUT
The knock sensor is only on these engines.
The knock sensor threads into the side of the cylinder block in front of the starter. When the knock
sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response,
the PCM retards ignition timing for all cylinders by a scheduled amount.
Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM.
As the intensity of the engine knock vibration increases, the knock sensor output voltage also
increases.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2281
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: ignition timing,
cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude
increases with the increase of engine knock. The knock sensor can be tested with a digital
voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to
approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2282
Knock Sensor: Service and Repair
Knock Sensor
The knock sensor threads into the side of the cylinder block in front of the starter.
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening
effects knock sensor performance, possibly
causing improper spark control.
2. Attach electrical connector to knock sensor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Specifications > Pressure, Vacuum and Temperature Specifications
Fuel Pressure: Pressure, Vacuum and Temperature Specifications
Fuel Pressure
Key On, Engine Off ..............................................................................................................................
......................................... (approx.) 338 kPa (49 psi)
Note: Using the DRB Scan Tool, access ASD Fuel System Test. The ASD Fuel System Test will
activate the fuel pump and pressurize the system.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain
energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off
position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure >
System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 2288
Fuel Pressure: Capacity Specifications
Information not supplied by the manufacturer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
Minimum Air Flow Idle Odometer <= 1000 Miles .................................................................................
.................................................................................................. 525-875 rpm Odometer >= 1000
Miles ....................................................................................................................................................
............................... 575-875 rpm
Note: Idle speed range achieved through Minimum Air Flow Idle Test
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > Page 2292
Idle Speed: Testing and Inspection
1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2.
Ensure that all accessories are off. 3. Shut off engine.
PCV Valve
4. Disconnect the PCV valve hose from the intake manifold nipple. 5. Cap the PCV valve nipple. 6.
Air Metering Fitting 6457
a. Install Air Metering Fitting 6457 (0.125 in. orifice) to the intake manifold PCV nipple. b.
Disconnect the idle purge line from the throttle body nipple.
7.
a. Cap the 3116 inch nipple. b. Connect the DRB scan tool to the data link connector.
8. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one
180°F cycle. 9. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen.
10. The following will then occur:
- Idle air control motor will fully close.
- Idle spark advance will become fixed.
- DRB scan tool displays engine rpm.
11. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum
air-flow is set correctly.
IDLE SPECIFICATION Odometer Reading = Idle RPM Below 1000 Miles = 525-875 RPM Above
1000 Miles = 575-875 RPM
12. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows:
a. Remove the throttle body from engine.
WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR
BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES
OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING
CLEANER.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > Page 2293
b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle body.
c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and
manifold side of the throttle blade. The edges of the
throttle blade and portions of the throttle bore that are closest to the throttle blade when closed,
must be free of deposits.
d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f.
Install throttle body on manifold.
g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is
not caused by the throttle body.
13. Shut off engine. 14. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple.
Reinstall the PCV valve hose. 15. Uncap the throttle body idle purge nipple and connect the idle
purge line. 16. Remove DRB scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
REMOVAL
Air Inlet Resonator
1. Remove 2 screws and air inlet resonator. 2. Loosen 3 clamps holding air cleaner housing halves
together.
Air Cleaner Housing (Left Side)
3. Remove left side of air cleaner housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair > Page 2298
Air Cleaner Element
4. Remove element from air cleaner housing.
INSTALLATION
1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4.
Install hoses and air inlet resonator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions > Page 2303
Fuel Pressure Release: Service and Repair
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap.
Fuel Pressure Test Port
Releasing Fuel Pressure
3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel
pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other
end of hose C-4799-1 to
fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container.
Fuel gauge C-4799-B contains hose C-4799-1.
5. Replace Pressure test port cap when finished doing pressure test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Firing Order
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications
Ignition Cable: Specifications
Cable = Maximum Resistance
#1 = 18.5 K Ohms
#2 = 15.5 K Ohms
#3 = 20.4 K Ohms
#4 = 21.2 K Ohms
#5 = 27.7 K Ohms
#6 = 26.7 K Ohms
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications > Page 2314
Ignition Cable: Description and Operation
DESCRIPTION
The spark plug cables and spark plug boots are made from high temperature silicon materials. The
spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The
heat shields slide over the spark plug boots. The notches on the heat shields ensure the spark plug
boot and shield twist together during spark plug boot removal. They also identify proper heat shield
installation on the boot for service. Refer to Spark Plug Cable Replacement. All spark plug cable
leads are properly identified with cylinder numbers. The inside of the spark plug boot is coated with
a special high temperature silicone grease for greater sealing and to minimize boot bonding to the
spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature
plastic material. Under normal driving conditions, the spark plug cables have a recommended
service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles
for severe driving conditions per schedule B.
The spark plug heat shield can be reused if an ignition cable is replaced due to failure. Never reuse
heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing.
Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. The
bottom of the spark plug heat shield must make contact with the spark plug hex.
The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not
touch the coil mounting bolt to avoid abrasion/dielectric failures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications > Page 2315
Ignition Cable: Service and Repair
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the ignition cables.
Spark Plug Boot/Heat Shield Orientation
The spark plug boot heat shield needs to be installed correctly on the boot before being installed on
the engine. If it is not installed correctly engine misfire would occur.
Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly.
Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely
important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield
must make contact with the spark plug socket hex.
CAUTION: Never coat the inside of spark plug boots with silicone grease. Some types of silicone
grease can damage the ignition cable conductor.
Spark Plug Cables # 3 And # 5
REMOVAL
1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the
spark plug. Twist the boot slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle.
This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug
insulator clean with a dry cloth before installation.
3. Remove the cable from the retaining bracket. Make sure that they are also detached from the
rear retaining clip mounted on the rear of the intake
manifold.
INSTALLATION
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated. A click sound should be heard
or terminal engagement is felt when the terminals are properly attached.
2. Install the cable into the retaining bracket. Make sure that they are also attached to the rear
retaining clip mounted on the rear of the intake
manifold.
3. Install the resonator.
Spark Plug Cable # 1
REMOVAL
1. Remove the accessory drive belt. 2. Remove the four bolts from the upper half of the generator
bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as
possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle.
This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug
insulator clean with a dry cloth before installation.
5. Remove the cable from the retaining bracket.
INSTALLATION
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated. A click sound should be heard
or terminal engagement is felt when the terminals are properly attached.
2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install
the accessory drive belt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications
Spark Plug: Specifications
Electrode Gap ......................................................................................................................................
.................................. 1.21-1.34 mm (0.048-0.053 in) Torque .............................................................
.............................................................................................................................................. 28 Nm
(20 ft lb)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2319
Spark Plug: Application and ID
Spark Plug ...........................................................................................................................................
............................................................... RN14PMP5 Thread .............................................................
................................................................................................................................................ (14mm)
3/4 in.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2320
Spark Plug: Description and Operation
SPARK PLUGS RESISTER
DESCRIPTION All engines use resistor spark plugs. They have resistance values ranging from
6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester.
Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Setting Spark Plug Electrode Gap
Refer to the Specifications for gap and type of spark plug.
SPARK PLUGS PLATINUM
DESCRIPTION The engine utilize platinum spark plugs. Refer to the maintenance schedule.
All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000
ohms when checked with at least a 1000 volt spark plug tester.
Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Platinum Pads
The spark plugs are double platinum and have a recommended service life of 100,000 miles for
normal driving conditions per schedule A. The spark plugs have a recommended service life of
75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both
electrode ends as shown. Extreme care must be used to prevent spark plug cross threading,
mis-gaping and ceramic insulator damage during plug removal and installation.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2321
Spark Plug: Testing and Inspection
Spark Plug Condition
Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken
porcelain insulators. Keep plugs arranged in the order in which they were removed from the
engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended.
Normal Operating Conditions
Normal Operation And Cold (Carbon) Fouling
The few deposits present will be probably light tan or slightly gray in color with most grades of
commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average
more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation for non
platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, and
then reinstalled.
CAUTION: Never attempt to tile the electrodes or use a wire brush for cleaning platinum spark
plugs. This would damage the platinum pads which would shorten spark plug life.
Some fuel refiners in several areas of the United States have introduced a manganese additive
(MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark
plug with a rust colored deposit. The rust color deposits can be mis diagnosed as being caused by
coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits.
Cold Fouling (Carbon Fouling) Cold fouling is sometimes referred to as carbon fouling because the
deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a
set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set
may be caused by a clogged air cleaner.
Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough
operating temperature during short operating periods. Replace carbon fouled plugs with new spark
plugs.
Fuel Fouling A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition
is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air
and reinstall them in the engine.
Oil Fouling A spark plug that is coated with excessive wet oil is oil fouled. In older engines, wet
fouling can be caused by worn rings or excessive cylinder wear. Break-in fouling of new engines
may occur before normal oil control is achieved. Replace oil fouled spark plugs with new ones.
Oil Or Ash Encrusted
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2322
Oil Or Ash Encrusted
If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the
combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of
spark plugs. Ash encrusted spark plugs can be cleaned and reused.
High Speed Miss When replacing spark plugs because of a high speed miss condition; wide open
throttle operation should be avoided for approximately 80 km (50 miles) after installation of new
plugs. This will allow deposit shifting in the combustion chamber to take place gradually and avoid
plug destroying splash fouling shortly after the plug change.
Electrode Gap Bridging
Electrode Gap Bridging
Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits
accumulate on the spark plugs during continuous stop-and-go driving. When the engine is
suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between
the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be
cleaned and reused.
Scavenger Deposits
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2323
Scavenger Deposits
Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a
normal condition caused by chemical additives in certain fuels. These additives are designed to
change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that
accumulation on the ground electrode and shell area may be heavy but the deposits are easily
removed. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and
reused.
Chipped Electrode Insulator
Chipped Electrode Insulator
A chipped electrode insulator usually results from bending the center electrode while adjusting the
spark plug electrode gap. Under certain conditions, severe detonation also can separate the
insulator from the center electrode. Spark plugs with chipped electrode insulators must be
replaced.
Preignition Damage
Preignition Damage
Excessive combustion chamber temperature can cause preignition damage. First, the center
electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively
deposit free. Determine if the spark plugs are the correct type, as specified on the VECI label, or if
other operating conditions are causing engine overheating.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2324
Spark Plug Overheating
Spark Plug Overheating
Overheating is indicated by a white or gray center electrode insulator that also appears blistered.
The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of
operation. This suggests that a plug with a cooler heat range rating should be used. Over
advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug
overheating.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2325
Spark Plug: Service and Repair
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
server injury/burns and can cause damage to the ignition cables.
Spark Plug Boot/Heat Shield Orientation
Use extreme care when removing and installing the spark plug cables. The spark plug boot heat
shield needs to be installed correctly on the boot before being installed on the engine. If it is not
installed correctly engine misfire would occur.
Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly
Spark Plug # 3 AND # 5
REMOVAL
1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen
bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as
close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with
the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug
boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation.
Wipe spark plug insulator]ator clean with a dry cloth before installation.
6. Remove spark plug
INSTALLATION
1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables,
make sure spark plug insulator and terminals are fully seated. A click sound should be heard or felt
when
the terminals are properly attached.
3. Install the cable into the retaining bracket. Make sure that they are also attached to the rear
retaining clip mounted on the rear of the intake
manifold.
4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6.
Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator.
Spark Plug # 1
REMOVAL
1. Remove the accessory drive belt. 2. Remove the 4 bolts from the upper half of the generator
bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as
possible to the spark plug. Twist the boot/shield assembly slightly to break its seal with
the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug
boot at an angle. This could damage the spark plug insulator, terminal, or the insulation. Wipe
spark plug insulator clean with a dry cloth before installation.
5. Remove spark plug
INSTALLATION
1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables,
make sure the coil or spark plug insulator and terminals are fully seated. A click sound should be
heard or
felt when the terminals are properly attached.
3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the
accessory drive belt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
Cylinder Compression Pressure:
Minimum 100 psi with no more than 25% variance between cylinders.
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System Information > Specifications > Page 2329
Compression Check: Testing and Inspection
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions.
Ensure the battery is completely charged and the engine starter motor is in good operating
condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traffic and other forms of congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators: fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For Direct
Ignition System, disconnect the coil connector.
5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage. Record
this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than
(689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended compression pressures are to be used only as a guide
to diagnosing engine problems. An engine should not be disassembled to determine the cause of
low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap. Tighten to specifications. 12. Test
resistance of spark plug cables. Refer to Powertrain Management. 13. Test coil output voltage,
primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at
idle and different RPM ranges.
Refer to Powertrain Management for Specifications.
15. The air filter elements should be replaced as specified. 16. Inspect crankcase ventilation
system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
The manufacturer indicates this engine is equipped with hydraulic lifters or lash adjusters and
therefore does not require adjustment.
See "Rocker Arm: Service and Repair" for further information.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor >
Component Information > Description and Operation
Battery Temperature Sensor: Description and Operation
OPERATION
The temperature sensor, in the PCM, is used to determine the battery temperature. This
temperature data, along with data from monitored line voltage, is used by the PCM to vary the
battery charging rate. System voltage will be higher at colder temperatures and is gradually
reduced at warmer temperatures.
The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II
monitors are either enabled or disabled depending upon the battery temperature sensor input
(example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions
Body Control Module: Technical Service Bulletins Electrical - Wiring Schematics Revisions
NUMBER: 26-12-99G
GROUP: Miscellaneous
DATE: December, 1999
THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revisions to the wiring schematics
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8W-44-5
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8W-44-7
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8W-45-7
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8W-50-2
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8W-50-5
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8W-50-7
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8W-80-15
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8W-90-3
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8W-90-11
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Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 2350
Body Control Module: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out
Revisions
NUMBER: 26-04-99
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
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8N-4
Revision to the Body Control Module connector pin-out
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8W-80-13
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Body Control Module: Technical Service Bulletins Body Control Module - Erroneous DTC Set
NO: 18-25-98
GROUP: Vehicle Performance
DATE: Aug. 14, 1998
SUBJECT: Erroneous Body Control Module Diagnostic Trouble Code
MODELS:
1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSAXLE.
DISCUSSION:
During service diagnostic procedures, the Body Control Module (BCM) may indicate an erroneous
"EATX PRNDL NOT RECEIVED" Diagnostic Trouble Code (DTC). If this DTC exists, turn the
ignition to the ON position and determine if each PRNDL indicator in the instrument cluster
becomes boxed (all boxed at the same time) after ten seconds. If all PRNDL indicators do NOT
become boxed at the same time, the DTC is erroneous and the DTC should be cleared, it is not
necessary to replace the BCM.
NOTE:
CHRYSLER HAS NOT RECEIVED ANY REPORTS OF THIS DTC BEING SET BY AN ACTUAL
FAILURE IN THE PRNDL SYSTEM.
POLICY: Information Only
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Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics
NO: 08-40-98
GROUP: Electrical
DATE: Sept. 25, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED
DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL
VEHICLES.
MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager
DISCUSSION:
During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp
Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head
lamps.
If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at
erasing this erroneous DTC will be unsuccessful.
If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan,
Voyager and Town & Country Body Diagnostic Procedures Manual.**
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Component Locations
Body Control Module: Component Locations
Body Control Module
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Component Information > Locations > Component Locations > Page 2357
Junction Block, Body Control Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Body Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Body Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Body Control Module: Connector Views
Body Control Module C1 (A)
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Body Control Module C2 (B)
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Junction Block
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Body Control Module Interconnect
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Body Control Module: Electrical Diagrams
BCM Block Diagram
Wiring Diagrams
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Body Control Module -- Sheet 8w-45-2
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Body Control Module -- Sheet 8w-45-3
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Body Control Module -- Sheet 8w-45-4
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Body Control Module -- Sheet 8w-45-5
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Body Control Module -- Sheet 8w-45-6
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Body Control Module -- Sheet 8w-45-7
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Body Control Module -- Sheet 8w-45-8
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Body Control Module -- Sheet 8w-45-9
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
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Body Control Module: Service Precautions
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
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Body Control Module: Description and Operation Part 1 of 3
INTRODUCTION
Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION
AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger
protection if the vehicle is involved in a front end collision. The system is most effective when used
in conjunction with the seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. This information will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
Functional Operation Whenever the ignition key is turned to the "run" or "start" position, the airbag
control module (ACM) performs a lamp check by turning the AIRBAG warning lamp ON. The lamp
stays lit for 6 to 8 seconds, then goes off. If the lamp remains OFF, it means that the ACM has
checked the system and found it to be free of discernible malfunctions. The airbag system is
monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures in this book to find the cause of any customer complaint regarding the
AIRBAG warning lamp, such as: warning lamp does not come on at all
- warning lamp stays on
BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with
visual and audible information and controls various vehicle functions. To provide and receive
information, the module is interfaced to the vehicle's serial bus communications network (the
Chrysler Collision Detection bus, or CCD bus). This network consists of the powertrain control
module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster
(MIC), the airbag control module (ACM), the compass/mini- trip module and the controller antilock
brake (CAB) module. The BCM is operational when battery power is supplied to the module.
Ignition switch power is needed for ignition switch functions.
The body control module provides the following features: automatic door locks
- battery protection
- CCD radio
- chimes
- compass/mini-trip support
- courtesy lamps
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
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- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid
wearing down the battery if the customer leaves the parklamps or headlamps on for extended
periods of time with the ignition OFF. If the parklamp or headlamp switch remains in the active
position for more than 3 minutes, while the ignition is OFF, the parklamps and or headlamps will be
turned off and the input causing the lamps to be ON will be ignored. Once the 3 minute time-out has
elapsed the BCM will enter sleep mode. Any change in any inputs monitored by the BCM that
brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock), door ajar,
ignition, RKE actuation, etc.).
Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory
power ON) will inhibit the battery protection routine from turning OFF the exterior lamps as
described above.
Battery Protect: "Reading & Glove Box Lamps" This feature provides a battery protection scheme to
avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity
mirrors ON. The BCM provides a ground circuit for these interior lamps. This ground path is
connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters
sleep mode. Once the 15 minutes time-out has expired, any monitored input that brings the BCM
out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central
Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and
vanity mirrors to normal operation (normal operation defined as: "ON" is reading lamp and visor
vanity mirrors ON, or glove box open; "OFF" if reading lamp and visor vanity mirrors OFF, and
glove box closed).
Leaving the keys in the ignition switch, while the ignition is OFF, will not inhibit the battery
protection from turning off these interior lamps as described above. Leaving the ignition switch in
an active position (steering column unlocked, ignition ON or accessory power on) will inhibit the
battery protection routine from turning off these interior lamps as described above.
Shipping Mode By definition, shipping mode is when the IOD fuse is removed from the vehicle. The
BCM receives its primary power feed from the battery via the IOD fuse. The BCM also receives a
back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry,
courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is
reconnected or the ignition switch is turned to the run/start position.
Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which
are controlled by the body controller module (BCM). When the parklamp switch is closed to ground
the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same
parklamp power feed is also wired back into the BCM to provide the power feed for the PWM
circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and
high beam headlamp relays. The position of the hi-beam select switch will determine the mode of
operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and
low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of
operation at a time.
Auto Headlamps On vehicles equipped with the auto headlamp feature, the BCM will control the
exterior lamp operation by monitoring the mode selection switch located in the headlamp control
panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the
Electro-Chromic Rear View mirror. The mirror will determine the appropriate ambient light levels for
turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to
darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see
Headlamp Delay Feature description).
Headlamp Time Delay The headlamp Delay feature keeps the Headlamps on for 60 seconds giving
the driver and passengers security lighting when exiting the vehicle. This feature is only available
on vehicles equipped with RKE. The Headlamp Delay feature is activated by sequentially turning
off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be
turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45
second window is new for the NS body Once the headlamp delay has been activated the
headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the
ignition switch changes states.
CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and
announcement. Warning chimes are provided for dome lamps on, engine temperature lamp,
exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above
15 mph). The warning chime will sound continuously until the condition is removed or the battery
protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for
approximately six seconds or until the seat belt is fastened, The announcement chime will sound
one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar
lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the
vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the
instrument cluster warning lamp diagnostics.
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Body Control Module: Description and Operation Part 2 of 3
COMPASS/MINI-TRIP COMPUTER
The compass/mini-trip computer is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE),
instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information
needed for the traveler functions is received over the CCD bus from the body control module.
If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration.
Setting The Compass The compass/mini-trip module is self-calibrated and requires no adjustment.
The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL
will turn off after the vehicle has gone in three complete circles without stopping, in an area free of
magnetic disturbance.
If the module displays the temperature while the compass is blank or shows a false reading, the
vehicle must be demagnetized. See the service procedure.
If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module
must be replaced.
Compass Magnetic Variance Zones
Setting The Variance Variance is the difference between magnetic north and geographic north. To
determine the variance for the area you are in, refer to the following zone map provided. The
number shown for your area is the variance number for your area. 1. Set the compass/mini-trip
console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5
seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the
variance to 8 and enter the fast calibration mode.
3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP
button to set the zone number. 5. Press the US/M button and resume normal operation,
NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO
THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS.
MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular
position of the gauges, the status of all CCD indicator lamps, the status and dimming of the
mechanical instrument cluster (MIC) over the CCD bus when the ignition is in the "off,, (unlock),
"run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the
ignition is in the "OFF" (unlock), "run", or "start" positions; all other MIC features work only when
ignition is in the "run position. On transition of the ignition from the "OF"' to the "run" position, a bulb
check is performed. This consists of activating all CCD controlled indicator lamps and all VF display
segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is
moved from the PARK position, or if the engine exceeds 450 rpm.
POWER DOOR LOCK SYSTEM When the BCM receives an input for a lock request (door lock
switch, RKE, or door key cylinder switch (only with VTSS)), it will ground the lock-relay coil for a
specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1
second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door
lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The
unlock signal operates in the same fashion as the lock signal. The door Lock switches provide a
variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the
BCM will respond to that command.
Other power Door Lock features: Sliding Door Memory Lock- When the BCM receives an input for
a lock request and a sliding door is open, the BCM will turn on the lock relay
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as described above, and will turn it on again when all sliding doors are closed.NOTE: If the BCM
receives an unlock input before a sliding door is closed this action will cancel the memory lock.
Door Lock Inhibit- When the key is in the ignition and in the off position, and any door except the
rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional.
This protects against locking the vehicle with the keys still in the ignition.
Automatic Door Locks- This feature can be enabled or disabled by using either the DRBIII or
customer programming method. When enabled, all the doors will lock when the vehicle reaches a
speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15
MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH.
RKE (Remote Keyless Entry) Interface- The body control module interfaces with the RKE receiver
via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the
BCM depending on which button on the transmitter was pressed. The BCM controls the door
lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The
RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the
PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the
RKE.
The RKE module can be programmed via the DRBIII or customer programming method. The BCM
will only allow programming mode to be entered when the ignition is in the ON position, the PRNDL
is in park position, and the VTSS (if equipped) is in the disarmed mode.
Programming an RKE Transmitter
Customer Programming Method
NOTE: A VALID, PREVIOUSLY PROGRAMMED TRANSMITTER MUST BE USED.
1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition on, place the transmission
in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3.
Using the previously programmed transmitter, press and hold the unlock button for 4 to 8 seconds.
While still holding the unlock button, press the panic button, then release both buttons. The BCM
will acknowledge that it has grounded the RKE module program enable wire by sounding a single
chime tone.
4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has
accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle
(up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode
sooner, turn the ignition off.
DRB Programming 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition ON,
place the transmission in park, and make sure the vehicle theft security system (if equipped) is in
disarm mode. 3. Select Program RKE" under "Miscellaneous". If the message "BCM is in
Programming Mode" does not appear, exit and select "Program
RKE" again.
4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has
accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle
(up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode
sooner, press "Back Page".
RADIO SYSTEM There are three radio systems available this year that will be on the CCD bus.
They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the
radio remote controls in the steering wheel. They can control volume up/ down, seek up, seek
down and preset station selections. These systems also communicate with the body control
module and will set a specific code if there is a problem with the remote controls.
The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of
the 4 main quarter speakers have a built in amplifier. The I/P and pillar speakers receive their
signals from the quarter speakers. Depending on the manufacture some systems will have a
Front/Rear channel system and others will have a Left/Right channel system. If one of the main
quarter speaker audio circuits experiences a short, the other speakers on that channel will also
shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible
with the DRB, indicating which channel is effected.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Part 1 of 3 > Page 2397
Body Control Module: Description and Operation Part 3 of 3
VEHICLE COMMUNICATION The body system consists of a combination of modules that
communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD
bus, information about the operation of vehicle components and circuits is relayed to the
appropriate module(s). Each module receives the same information about a component or circuit
as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and
the size of the wiring harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system called "bus +" (bus plus)
and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts.
In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded
messages, there is a "voltage divider network". This network consists of some modules with bias
and some with termination. Bias is the part of the voltage divider network that places both bus +
and bus - at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network
and also provides some electromagnetic protection for the bus.
NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF
THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE
OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH
DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE
COMMUNICATIONS.
Any of the following bus failure messages may be displayed. Short to Battery- Either or both of the
bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are
shorted to a 5-volt potential. Short to Ground- Either or both of the bus wires are shorted to ground
or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are
shorted together. No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly
above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules
that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus
Messages Correctly - The DRB cannot communicate over the bus and does not know why.
VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against theft.
The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle
hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the
horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an
engine "no run" feature.
Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's
door, locking the doors with the power lock, and closing the driver's door or locking the doors with
RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator
lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no
monitored systems are activated during this period, the system Will arm. If the hood ajar switch is
seen as closed circuit by the system, the indicator lamp Will remain steadily lit during the arming
process, although the system will still arm.
When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for
about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate
is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override -
The system will not arm if the doors are locked using the manual lock control (by hand) or if the
locks are actuated by an inside occupant after the door is closed.
When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus
to the powertrain control module that it is not OK to start the engine. The powertrain control module
then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting
down the engine (start and stall condition). The engine will not start until the system is disarmed.
To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but
keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE:
After the doors are closed, locking the doors with RKE will also arm the system.
NOTE: IF THE VTSS INDICATOR LAMP FLASHED, THE SYSTEM IS OPERATIONAL AND
VERIFIED. IF NOT, THERE MAY BE A PROBLEM WITH THE SYSTEM.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Part 1 of 3 > Page 2398
System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is
closed. 1. Rotating the key in liftgate cylinder to unlock/disarm position.
Arming/Disarming- Active arming occurs when the remote keyless entry transmitter is used to lock
the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming
sequence is completed only after all door are closed.
Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with
the key). This disarming also will halt the alarm once it has been activated.
Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle
doors. This disarming also will halt the alarm once it has been activated.
System Self-Test - NOTE: System self-test can be entered only with the DRB.
NOTE: A POWERTRAIN CONTROL MODULE FROM A VEHICLE EQUIPPED WITH A VEHICLE
THEFT SECURITY SYSTEM CANNOT BE USED IN A VEHICLE THAT IS NOT EQUIPPED WITH
A VEHICLE THEFT SECURITY SYSTEM.
If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication
with the powertrain control module possibly has been lost.
WIPER SYSTEM
Front The front wiper system provide the driver with normal wipe (low and high speeds),
intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function
via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the
on position and the ignition is turned OFF the wiper will continue to run until it reaches its park
position.
Other front wiper system features: Speed Sensitive Intermittent Wipe Mode- There are 6 individual
delay times with minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle
speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36
seconds.
Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more
than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided.
Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then
releases it, the wiper will continue to run for 2 additional wipe cycles.
Rear The rear wiper system provides the driver with continuous, intermittent, and wiper after wash
functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the
HVAC control.
DRB III (R) ERROR MESSAGES
Under normal operation, the DRB will display one of only two error messages: - User-Requested
WARM Boot or User- Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the MDS
Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error
message display:
ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD
Boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRB III (R) Does Not Power UP (Blank Screen) If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data
link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Part 1 of 3 > Page 2399
DRB Scan Tool
Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to
compensate for this condition
WARNINGS
Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is
"OFF". Failure to do so could damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair
verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or
symptom condition.
CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE
REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN
WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE
IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB.
REQUIRED TOOLS AND EQUIPMENT
DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires
ohmmeter voltmeter oil pressure gauge (0-300 psi) test light
GLOSSARY OF ACRONYMS
ACM Airbag Control Module
AECM Airbag Electronic Control Module (type of ACM)
ASDM Airbag System Diagnostic Module (type of ACM)
BCM body control module
CAB controller antilock brake
CCD Chrysler Collision Detection (vehicle communications bus)
CMTC
Compass/Mini-Trip Computer (module)
DLC data link connector (previously called "engine diagnostic connector")
DR driver
HVAC heater, ventilation, air condition
MET metric
MIC mechanical instrument cluster
MUX multiplexed
ODO odometer
PASS passenger
PCM powertrain control module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Part 1 of 3 > Page 2400
PDC powertrain distribution center
PTC positive temperature coefficient
RKE remote keyless entry
TCM transmission control module
VF vacuum fluorescent display
VTSS
vehicle theft security system
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures
Body Control Module: Symptom Related Diagnostic Procedures
AM/FM Switch Inoperative
SYMPTOM
* AM/FM SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Balance Joystick Inoperative
SYMPTOM
* BALANCE JOYSTICK INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Cassette Error
SYMPTOM
CASSETTE ERROR
POSSIBLE CAUSES
- Cassette Error / Replace radio
CD Eject Switch Inoperative
SYMPTOM
* CD EJECT SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
CD Error
SYMPTOM
CD ERROR
POSSIBLE CAUSES
- Defective radio
Equalizer Inoperative
SYMPTOM
* EQUALIZER INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
External CD Changer (If Equipped)
SYMPTOM
* EXTERNAL CD CHANGER (IF EQUIPPED)
POSSIBLE CAUSES
- Radio/CD cable loose/disconnected
- DIN cable data bus (CAV 1) open
- DIN cable data bus (CAV 3) open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2403
- DIN cable terminals shorted
- DIN signal wires (CAVS 2, 4, and 5) open
- DIN fused B(+) circuit open
- DIN fused ignition switch output circuit open
- DIN ground circuit open
- DIN metal connectors open
- Radio defective
- Radio input control defective
FF/RW Switch Inoperative
SYMPTOM
* FF/RW SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Hour/Minute Switch Inoperative
SYMPTOM
* HOUR/MINUTE SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
No Sound From All Speakers
SYMPTOM
* NO SOUND FROM ALL SPEAKERS
POSSIBLE CAUSES
- Radio 12V output circuit defective, open
- Radio ground circuit defective, open
- Power relay output circuit defective, open
- Radio 12V output circuit shorted to ground
- Radio choke defective
- Speaker power relay defective, open
- Speaker power relay defective, open
- Junction block defective, open circuit
- Defective radio
- Radio choke output circuit defective, open
- Radio output circuits defective
No Sound From One Speaker
SYMPTOM
* NO SOUND FROM ONE SPEAKER
POSSIBLE CAUSES
- Door or quarter speaker (+) circuit defective, open
- Door or quarter speaker (-) circuit defective, open
- Door or quarter speaker (+) circuit open
- Door or quarter speaker (-) circuit open
- Instrument panel or pillar speaker (+) circuit open
- Instrument panel or pillar speaker (-) circuit open
- Door or quarter speaker defective
- Speaker defective, no response
Pause/Play Switch Inoperative
SYMPTOM
* PAUSE/PLAY SWITCH INOPERATIVE
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2404
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Poor Sound Quality All Speakers
SYMPTOM
* POOR SOUND QUALITY ALL SPEAKERS
POSSIBLE CAUSES
- Antenna connector defective
- Antenna connections defective
- Hood ground defective
- Ground circuit defective, open
- Radio connectors not properly connected
- Ignition / alternator system noise
- Radio defective
Poor Sound Quality From One Speaker
SYMPTOM
* POOR SOUND QUALITY FROM ONE SPEAKER
POSSIBLE CAUSES
- Ground circuit open
- Instrument panel - pillar speaker defective
- Radio choke output circuit open
- Speaker (+) and (-) circuits shorted together
- Inoperative speaker defective
PWR Switch Inoperative
SYMPTOM
* PWR SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Radio Error
SYMPTOM
RADIO ERROR
POSSIBLE CAUSES
- Defective radio
Remote Controls Inoperative
SYMPTOM
* REMOTE CONTROLS INOPERATIVE
POSSIBLE CAUSES
- No response, CCD bus failure
- Radio control harness defective, open
- Radio control MUX circuit shorted
- Remote control switch defective
- MUX control clockspring defective
- Radio control ground circuit to BCM open
- Radio control MUX circuit open
- Radio MUX control circuit defective
- Body Control Module defective
Scan Switch Inoperative
SYMPTOM
* SCAN SWITCH INOPERATIVE
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2405
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Seek Switch Inoperative
SYMPTOM
* SEEK SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Set Switch Inoperative
SYMPTOM
* SET SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Shorted Front Channel
SYMPTOM
SHORTED FRONT CHANNEL
POSSIBLE CAUSES
- Left door speaker shorted
- Left front instrument panel speaker shorted
- Right door speaker shorted
- Right front instrument panel speaker shorted
- Right front (-) circuit shorted to ground
- Right front (+) and (-) circuits shorted together
- Right front (+) circuit shorted to ground
- Left front (+) and (-) circuits shorted together
- Left front (+) circuit shorted to ground
- Left front (-) circuit shorted to ground
- Radio output circuits defective
Shorted Left Channel
SYMPTOM
SHORTED LEFT CHANNEL
POSSIBLE CAUSES
- Left door speaker defective, shorted
- Left front instrument panel speaker defective, shorted
- Left quarter speaker shorted
- Left rear (+) and (-) circuits shorted together
- Left rear (+) circuit shorted to ground
- Left rear (-) circuit shorted to ground
- Left rear speaker shorted
- Left front (+) and (-) circuits shorted together
- Left front (+) circuit shorted to ground
- Left front (-) circuit shorted to ground
- Radio output circuits defective
Shorted Rear Channel
SYMPTOM
SHORTED REAR CHANNEL
POSSIBLE CAUSES
- Right rear quarter speaker shorted
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2406
- Left rear (+) and (-) circuits shorted together
- Left rear (+) circuit shorted to ground
- Left rear (-) circuit shorted to ground
- Left rear quarter speaker shorted
- Left rear speaker shorted
- Right rear (+) and (-) circuits shorted together
- Right rear (+) circuit shorted to ground
- Right rear (-) circuit shorted to ground
- Right rear pillar speaker shorted
- Radio output circuits defective
Shorted Right Channel
SYMPTOM
SHORTED RIGHT CHANNEL
POSSIBLE CAUSES
- Right channel speaker shorted
- Right instrument panel speaker defective, shorted
- Right front (+) circuit shorted to ground
- Right front (+) and (-) circuits shorted together
- Right front (-) circuit shorted to ground
- Right pillar speaker shorted
- Right quarter speaker shorted
- Right rear (+) and (-) circuits shorted together
- Right rear (+) circuit shorted to ground
- Right rear (-) circuit shorted to ground
- Radio output circuits defective
Tape Eject Switch Inoperative
SYMPTOM
* TAPE EJECT SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Tune Switch Inoperative
SYMPTOM
* TUNE SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Volume/Time Switch Inoperative
SYMPTOM
* VOL/TIME SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
1-5 Presets Inoperative
SYMPTOM
* 1-5 PRESETS INOPERATIVE
POSSIBLE CAUSES
- Radio function controls inoperative
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2407
Chime Inoperative at All Times
SYMPTOM
* CHIME INOPERATIVE AT ALL TIMES
POSSIBLE CAUSES
- BCM fails chime test
Chime Inoperative With Driver Seat Belt Unfastened
SYMPTOM
* CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED
POSSIBLE CAUSES
- Ground circuit to left seat belt switch connector open
- Left seat belt switch open
- BCM not responding to belt switch
- Body Control Module seat belt switch sense open
- Seat belt switch sense circuit open
Chime Inoperative With Engine Temperature Critical
SYMPTOM
* CHIME INOPERATIVE WITH ENGINE TEMPERATURE CRITICAL
POSSIBLE CAUSES
- BCM - No response to oil pressure
- BCM fails chime test
Chime Inoperative With Exterior Lamps On
SYMPTOM
* CHIME INOPERATIVE WITH EXTERIOR LAMPS ON
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition Switch - key in switch shorted
- BCM - no chime response - head/park lamps ON
- BCM - key in sense shorted default
- BCM - no response to park lamp switch
- Chime inoperative with exterior lamps ON
Chime Inoperative With Key In Ignition & Driver Door Open
SYMPTOM
* CHIME INOPERATIVE WITH KEY IN IGNITION & DRIVER DOOR OPEN
POSSIBLE CAUSES
- Ignition switch ground circuit open
- Key in ignition switch sense circuit open
- Ignition switch - key in switch open
- BCM - no chime to key in ignition
- BCM not responding to key in switch
Chime Inoperative With L or R Turn Signal On For 1 Mile
SYMPTOM
* CHIME INOPERATIVE WITH LEFT OR RIGHT TURN SIGNAL ON FOR 1 MILE
POSSIBLE CAUSES
- Junction block - Left turn signal open
- Junction block - Right turn signal open
- BCM - no response to turn signal
- BCM fails speed test
- Chime - speedometer problem
- Chime inoperative - turn signal on for 1 mile
Chime Inoperative With Low Oil Pressure
SYMPTOM
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2408
* CHIME INOPERATIVE WITH LOW OIL PRESSURE
POSSIBLE CAUSES
- BCM - No response to oil pressure
- BCM fails chime test
Chime Inoperative With the Dome Lamps On
SYMPTOM
* CHIME INOPERATIVE WITH THE DOME LAMPS ON
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition switch - key in switch shorted
- BCM failed - door open & key out default
- BCM - key in switch sense shorted default
Chime Sounds With Driver Door Open & Key Out
SYMPTOM
* CHIME SOUNDS WITH DRIVER DOOR OPEN & KEY OUT
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition switch - key in switch shorted
- BCM - key in switch sense shorted default
- BCM not responding to key out
Chime Sounds With Driver Seat Belt Fastened
SYMPTOM
* CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED
POSSIBLE CAUSES
- Seat belt switch sense circuit shorted to ground
- Left seat belt switch shorted
- BCM - no response to seat belt fastened
- BCM seat belt switch input shorted to ground
Auto Headlamps Will Not Turn Off
SYMPTOM
* AUTO HEADLAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- No response (PCM) - CCD bus failure
- Auto headlamp signal circuit open
- Auto headlamp signal circuit shorted to ground
- Electrochromic mirror defective - sensor stuck ON (default)
- BCM defective - auto headlamp sensor stuck ON
Auto Headlamps Will Not Turn On
SYMPTOM
* AUTO HEADLAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- NO response (BCM) - CCD bus failure
- NO response (PCM) - CCD bus failure
- Auto headlamp signal circuit open
- Electrochromic mirror defective (default)
- BCM defective - auto headlamp sensor
Fog Lamps Will Not Turn Off
SYMPTOM
* FOG LAMPS WILL NOT TURN OFF
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2409
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Fog lamp switched ground circuit shorted to ground
- Headlamp switch defective - foglamp switched ground
Fog Lamps Will Not Turn On
SYMPTOM
* FOG LAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Fog lamp bulbs open
- Fog lamp relay control circuit open
- Fog lamp relay output circuit open
- Fog lamp relay defective, open
- Multifunction dimmer switch defective (open) default
- Fog lamp switched ground circuit open
- BCM defective - Headlamp relay control
- Multifunction switch defective (fog lamp relay control) default
- Headlamp relay control circuit (foglamps) open
Headlamps Will Not Turn Off
SYMPTOM
* HEADLAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch sense circuit shorted to ground
- Headlamp relay control circuit shorted to ground
- Low beam relay control circuit shorted to ground
- Low beam relay control circuit (QUAD) shorted to ground
- Low beam headlamp relay (QUAD) defective, shorted
- Low beam headlamp relay defective (shorted) by default
- PDC defective (low beam headlamp relay connector shorted)
- Headlamp switch defective - switch sense
- BCM defective (headlamp switch sense function) by default
- BCM defective (low beam relay control shorted) by default
Headlamps Will Not Turn On
SYMPTOM
* HEADLAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch ground circuit open
- Both low beam fuses open
- Fused low beam output circuit open (both lamps inoperative)
- Fused low beam output circuit open (one lamp inoperative)
- Headlamp defective (by default)
- Headlamp fuse open
- Headlamp switch sense circuit open
- Headlamps defective (by default)
- Multifunction switch defective (default)
- Headlamp relay control circuit open
- Low beam relay control circuit (Chrysler) open
- Low beam relay control circuit open
- Low beam headlamp relay defective (by default)
- Low beam relay defective - relay control function
- PDC defective - B(+) circuit at low beam fuse terminal
- Power Distribution Center defective (low beam relay CAV A)
- Power Distribution Center defective (low beam relay CAV B)
- Headlamp switch defective (by default)
- BCM defective - headlamp switch sense function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2410
- BCM defective - headlamp switch sense stuck open
- BCM defective - low beam relay control open
Park Lamps Will Not Turn Off
SYMPTOM
* PARK LAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Park lamp relay control circuit shorted to ground
- Park lamp relay output circuit shorted to voltage
- Park lamp switch sense circuit shorted to ground
- Park lamp relay defective - control shorted (by default)
- Headlamp switch defective - shorted
- BCM defective - park lamp switch sense closed (by default)
Park Lamps Will Not Turn On
SYMPTOM
* PARK LAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch ground circuit open
- Fused park lamp output circuit open
- Park lamp bulb defective (by default)
- Park lamp fuse in PDC open
- Both park lamp fuses open
- Park lamp fuse open
- Park lamp relay control circuit open
- Park lamp relay output circuit open
- Park lamp switch sense circuit open
- Park lamp relay defective (control function)
- PDC defective - other B(+) cavity
- PDC defective - park lamp relay connector, fused B(+)
- Headlamp switch defective - park lamps (by default)
- BCM defective - park lamp switch sense stuck open
- BCM defective - park lamp switch sense function
- BCM defective - parklamp control function (by default)
ABS Warning Lamp
SYMPTOM
* ABS WARNING LAMP
POSSIBLE CAUSES
- BCM connector observable defect
- CAB connector observable defect
- Fused ignition switch output circuit open
- ABS warning lamp defective
- ABS warning lamp driver circuit open
- ABS warning lamp driver circuit shorted to ground
- ABS warning lamp flashing
- BCM defective
- CAB defective
Airbag Warning Lamp
SYMPTOM
* AIRBAG WARNING LAMP
POSSIBLE CAUSES
- Airbag warning lamp failure
All Warning Lamps Out
SYMPTOM
* ALL WARNING LAMPS OUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2411
POSSIBLE CAUSES
- Fused B(+) circuit open
- Fused ignition switch output circuit open
- Ground circuit open
- Information Center defective
Engine Temperature Warning Lamp
SYMPTOM
* ENGINE TEMPERATURE WARNING LAMP
POSSIBLE CAUSES
- Engine temperature lamp staying on
- Temperature lamp not working
- Engine temperature lamp/bulb defective
- Fused ignition switch output circuit open
- Defective BCM
- Engine temperature warning lamp driver circuit open
- Temperature warning lamp driver circuit shorted to ground
- Information Center defective
- Body Control Module defect
- Defective Information Center
High Beam Indicator Lamp
SYMPTOM
* HIGH BEAM INDICATOR LAMP
POSSIBLE CAUSES
- Headlamps inoperative
- Fused right highbeam output circuit open
- Ground circuit open
- High beam indicator bulb defective
- Defective Information Center
Low Oil Pressure Warning Lamp
SYMPTOM
* LOW OIL PRESSURE WARNING LAMP
POSSIBLE CAUSES
- Oil pressure low
- Oil warning lamp/bulb defective
- Oil level low
- Defective oil pressure switch
- Oil pressure switch sense circuit shorted to ground
- Oil pressure switch sense circuit open
- Oil pressure switch defective
- BCM defective
- Defective Information Center
Red Brake Warning Lamp
SYMPTOM
* RED BRAKE WARNING LAMP
POSSIBLE CAUSES
- Park brake pedal problem
- Vehicle equipped antilock brakes
- Brake fluid level low
- Red brake warn lamp/bulb defective
- Ground circuit open
- Brake fluid level switch defective
- Defective ignition switch
- Defective park brake switch
- Red brake warning lamp circuit open
- Red brake warning lamp circuit shorted to ground
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2412
- Information Center faulty
- Ignition switch defective
- Red brake warning lamp driver circuit open
- Red brake warning lamp driver circuit faulty
Service Engine Soon Lamp
SYMPTOM
* SERVICE ENGINE SOON LAMP
POSSIBLE CAUSES
- DTC's are present
- Bulb & socket defective
- Service Engine Soon indicator lamp driver circuit open
- Service Engine Soon indicator lamp circuit shorted to ground
- Defective Information Center circuit board
- Powertrain Control Module defective
Turn Signal Indicator Lamp
SYMPTOM
* TURN SIGNAL INDICATOR LAMP
POSSIBLE CAUSES
- Turn signal lamps inoperative
- Ground circuit open
- Left turn signal circuit open
- Right turn signal circuit open
- Turn signal bulbs defective
- Junction Block defective
- BCM defective
- Information Center defective
Vehicle Theft Alarm Indicator
SYMPTOM
* VEHICLE THEFT ALARM INDICATOR
POSSIBLE CAUSES
- Vehicle theft alarm indicator defective
All Gauges Inoperative
SYMPTOM
* ALL GAUGES NOT OPERATING
POSSIBLE CAUSES
- BCM instrument cluster circuit output defective
- Instrument Cluster PC board defective
- DRB shows ignition unlock closed
- No response - CCD bus instrument cluster
- Body computer odometer failure
- RAM test failure
- ROM test failure
Cluster Illumination
SYMPTOM
* CLUSTER ILLUMINATION
POSSIBLE CAUSES
- No response - CCD bus instrument cluster
- Headlamp switch ground circuit defective
- Inoperative lamp defective
- Headlamp switch defective
- Junction block defective
- Dimmer switch signal circuit open
- Dimmer switch signal circuit shorted to ground
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2413
- Instrument panel lamps driver circuit shorted to ground
- Panel lamps driver circuit open
- Park lamps not lighting
- Instrument Cluster circuit board defective
- BCM dimmer switch signal circuit output faulty
- BCM defective
- BCM defective by default
- Body computer odometer failure
- BCM dimmer switch signal circuit defective
- Illumination panel fuse OK
- Inoperative lamp ground circuit
- RAM test failure
- ROM test failure
Cluster Warning Lamps Odometer and PRNDL Display
SYMPTOM
* CLUSTER WARNING LAMPS ODOMETER AND PRNDL DISPLAY
POSSIBLE CAUSES
- Any one lamp/bulb defective
- Washer fluid level switch sense circuit open
- Washer fluid level switch sense ground circuit open
- Washer fluid level switch sense circuit shorted
- Body computer odometer failure DTC
- No response - CCD bus instrument cluster
- Washer fluid level switch defective
- BCM washer fluid switch sense circuit input defective
- All segments fail to light
- Faulty odometer and PRNDL lamp
- Generator lamp failure
- Instrument cluster printed circuit board defective
Gauges Not Returning to Zero With Key Off
SYMPTOM
* GAUGES NOT GOING TO ZERO WHEN KEY IS TURNED OFF
POSSIBLE CAUSES
- Fused B(+) circuit open
- No response - CCD bus instrument cluster
- Instrument Cluster PC board defective
- Body computer odometer failure
- RAM test failure
- ROM test failure
One Gauge Not Operating Properly
SYMPTOM
* ONE GAUGE OPERATING IMPROPERLY
POSSIBLE CAUSES
- DRB reads active on the bus
- DRB reads no vehicle speed sense signal code
- IOD fuse is loose in junction block
- Speedometer calibration out
- Any one lamp/bulb defective
- DRB reading not matching RPM
- Washer fluid level switch sense circuit open
- Washer fluid level switch sense ground circuit open
- Washer fluid level switch sense circuit shorted
- Washer fluid level switch defective
- Gauge pack defective
- Speedometer/Odometer gauge pack defective
- Tachometer calibration out
- Cooling system condition faulty
- DRB reads coolant temperature sensor code
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2414
- DRB reads engine temperature accurately
- BCM instrument cluster circuit output defective
- Body Control Module defective
- Gauge pack defective
- Instrument Cluster printed circuit board defective
- DRB shows ignition unlock closed
- BCM washer fluid level switch sense circuit input defective
- All segments fail to light
- BCM temperature gauge input defective
- Faulty odometer and PRNDL lamp
- Generator lamp failure
- PCM defective
- Pinion factor failure
Trip and Rest Button(S)
SYMPTOM
* TRIP AND RESET BUTTON(S)
POSSIBLE CAUSES
- Trip & reset button(s) defective
Courtesy Lamps Inoperative W/Dome Lamp Switch
SYMPTOM
* COURTESY LAMPS INOPERATIVE W/DOME LAMP SWITCH
POSSIBLE CAUSES
- Courtesy lamp switch sense circuit open
- Headlamp switch defective - courtesy lamp function open
- BCM defective - courtesy lamp switch sense (by default)
- BCM defective - dome lamp switch function
Courtesy Lamps Inoperative With Any Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH ANY DOOR
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Courtesy lamp relay control circuit open
- Switched courtesy lamp relay control circuit open
- Junction block defective - lamp relay fused B(+) (CAV 87) open
- Courtesy lamp relay defective - coil open
- Junction block defective - lamp relay fused B(+) (CAV 30) open
- Junction block defective - lamp relay fused B(+) (CAV 86) Open
- Headlamp switch defective - open
- BCM defective - lamp relay control function (by default)
- BCM defective - driver door ajar switch status
Courtesy Lamps Inoperative With Driver Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH DRIVER DOOR
POSSIBLE CAUSES
- Driver door ajar switch defective, open
- Driver door ajar switch sense circuit open
- Left front door switch ground strap corroded/damaged
- Body Control Module inoperative, open
Courtesy Lamps Inoperative With Left Sliding Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH LEFT SLIDING DOOR
POSSIBLE CAUSES
- Left sliding door ajar switch sense circuit open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2415
- Left sliding door ajar ground circuit open
- Left sliding door ajar switch defective, open
- BCM defective
Courtesy Lamps Inoperative With Liftgate
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH LIFTGATE
POSSIBLE CAUSES
- Liftgate ground circuit open
- Liftgate ajar switch open - ajar switch disconnected
- Liftgate ajar switch sense circuit open
- BCM defective, open
Courtesy Lamps Inoperative With Passenger Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH PASSENGER DOOR
POSSIBLE CAUSES
- Passenger door ajar switch defective, open
- Passenger door ajar switch sense circuit open
- Right front door switch ground strap corroded/damaged
- Body Control Module inoperative, open
Courtesy Lamps Inoperative With Right Sliding Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH RIGHT SLIDING DOOR
POSSIBLE CAUSES
- Right sliding door ajar switch defective, open
- Right sliding door ajar switch sense circuit open
- Right sliding door ajar ground circuit open
- BCM defective, open
Courtesy Lamps On at All Times
SYMPTOM
* COURTESY LAMPS ON AT ALL TIME
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Courtesy lamp relay output circuit shorted to B(+)
- Courtesy lamp relay control circuit shorted to ground
- Switched courtesy lamp relay control circuit shorted to ground
- Courtesy lamp relay defective - coil shorted
- Headlamp switch shorted
- BCM defective - relay control shorted (by default)
Illuminated Entry Inoperative With Driver Door Key Cylinder
SYMPTOM
* ILLUMINATED ENTRY INOPERATIVE WITH DRIVER DOOR KEY CYLINDER
POSSIBLE CAUSES
- Driver door key switch unlock position stuck
- Driver door key cylinder switch defective
- Driver door key switch sticking
Illuminated Entry Inoperative With RKE Transmitter
SYMPTOM
* ILLUMINATED ENTRY INOPERATIVE WITH RKE TRANSMITTER
POSSIBLE CAUSES
- RKE circuit at BCM defective
- RKE ground circuit open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2416
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- Defective door lock switch
- Defective unlock switch
- RKE module default replacement
- RKE module defective
CMTC Avg MPH/Fuel Economy Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE OR
WRONG
POSSIBLE CAUSES
- No PCM communications
- TPS inoperative
- VSS signal inoperative
CMTC Elapsed Time Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER ELAPSED TIME INOPERATIVE OR WRONG
POSSIBLE CAUSES
- Defective BCM / Indicator lights
CMTC Fails to Respond to Instrument Cluster Dimming
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER
DIMMING
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer
CMTC Trip Odometer Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER TRIP ODOMETER INOPERATIVE OR WRONG
TEST NOTE
This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER AVG MPH OR
FUEL ECONOMY INOPERATIVE/WRONG.
POSSIBLE CAUSES
- No PCM communications
- TPS inoperative
- VSS signal inoperative
Compass/Mini-Trip Computer Displaying OC
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER DISPLAYING OC
POSSIBLE CAUSES
- Open sensor ground circuit
- Ambient Temperature Sensor defective
- Open Ambient Temperature Sensor signal circuit
- Defective Compass/Mini-Trip Module - sensor ground circuit.
Compass/Mini-Trip Computer Displaying SC
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER DISPLAYING SC
POSSIBLE CAUSES
- Defective Ambient Temperature Sensor
- Ambient Temperature Sensor signal circuit shorted to ground
- Compass/Mini-Trip Module default
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2417
Compass/Mini-Trip Computer Segments Fail to Light
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SEGMENTS FAIL TO LIGHT
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer - segments fail to light
Compass/Mini-Trip Computer Shows Failed
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SHOWS FAILED
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer - shows failed
Compass/Mini-Trip Computer Switch Inoperative
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER FAILS TO
RESPOND TO INSTRUMENT CLUSTER DIMMING.
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer
Incorrect Ambient Temperature Readings
SYMPTOM
* INCORRECT AMBIENT TEMPERATURE READINGS
POSSIBLE CAUSES
- Open sensor ground - defective CMTM
- Sensor ground circuit partial short to ground
- Defective Ambient Temperature Sensor/Road test
- Ambient Temperature Sensor signal circuit partial short
- Ambient Temperature Sensor signal circuit shorted
- Defective Compass/Mini-Trip Module
- Defective Compass/Mini-Trip Module sensor ground circuit
Add'l All Doors (Exc Drvr w/RKE) Fail Lck/Unlckfrom Any Switch
SYMPTOM
ADDITIONAL ALL DOORS (EXCEPT DRVR W/RKE) FAIL LCK/UNLCK FROM ANY SWITCH
POSSIBLE CAUSES
- Junction block defective
- Door unlock relay output circuit open
- Door unlock relay output circuit resistance low
Additional All Doors (Exc Driver w/RKE) Fail to Unlock
SYMPTOM
ADDITIONAL ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK
POSSIBLE CAUSES
- Fused B(+) circuit voltage too low at junction block
- Door unlock relay control inoperative at BCM
- Door unlock relay defective
- Door unlock relay coil resistance out of tolerance
- Door unlock relay output circuit shorted to ground
Additional All Doors Fail to Lock and Unlock From Any Switch
SYMPTOM
* ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2418
POSSIBLE CAUSES
- Passenger door switch MUX shorted to battery
- Door lock switch resistance high in unlock position
- Driver door switch MUX circuit shorted to battery
- Liftgate switch MUX shorted to battery
- BCM door lock relay control circuit inoperative
- Liftgate switch MUX at BCM defective
- Door lock relay control ground circuit open
- Door lock relay defective
- Fuse # 26 defective
- Fused B(+) circuit open
- Fused B(+) circuit shorted to ground
- Ground circuit open at door lock relay connector
Additional All Doors Fail to Lock and Unlock From One Switch
SYMPTOM
ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH
POSSIBLE CAUSES
- Door key cylinder switch connector circuit ground circuit open
- Door key cylinder switch defective
- Liftgate key cylinder switch defective
- Liftgate switch MUX shorted to battery
- Door switch MUX circuit to BCM open
- Driver door switch MUX circuit open at BCM connector
- Liftgate switch MUX circuit open at BCM connector
- Liftgate switch MUX circuit to BCM open
- Passenger door switch MUX circuit open at BCM connector
- Passenger door switch MUX circuit to BCM open
- Door lock switch connector ground circuit open
- Door lock switch defective
- Door lock switch MUX circuit open
- Door locks inoperative from key cylinder switch
- Door switch MUX circuit shorted to battery
Additional All Doors Failing to Lock From Any Switch
SYMPTOM
ADDITIONAL ALL DOORS FAILING TO LOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Fused B(+) circuit voltage too low at junction block
- Door lock relay control circuit from BCM fails
- Key - in ignition switch circuit to BCM defective
- Door lock relay does not operate
- Door lock relay coil resistance out of tolerance
- Door lock relay output shorted to ground
- Ignition switch defective
- Key - in ignition switch sense circuit shorted to ground
Additional Driver Door (w/RKE) Failing to Unlock From Any SW
SYMPTOM
ADDITIONAL DRIVER DOOR (W/RKE)FAILING TO UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Driver door unlock relay coil resistance out of tolerance
- Driver door unlock relay defective
- Driver door unlock relay output circuit shorted to ground
- Voltage too low at junction block fused B(+) circuit
Additional One Door Fails to Lock and Unlock From Any Switch
SYMPTOM
ADDITIONAL ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2419
POSSIBLE CAUSES
- RKE equipped door lock fails to lock & unlock
- Door lock motor defective
- Driver unlock relay ground open in junction block
- Door lock relay output circuit open
- Door unlock relay output circuit open
- Driver door unlock relay open
All Doors (Exc Driver w/RKE) Fail Lock/Unlock From Any Switch
SYMPTOM
* ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors (Exc Driver w/RKE) Fail to Unlock
SYMPTOM
* ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK
POSSIBLE CAUSES
- RKE circuit at BCM defective
- RKE ground circuit open
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- Defective door lock switch
- Defective door unlock switch
- RKE module default replacement
- RKE module defective
All Doors Fail to Lock and Unlock From Any Switch
SYMPTOM
* ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Link to body communication bus inoperative
- Defective door lock switch
- Defective unlock switch
All Doors Fail to Lock and Unlock From One Switch
SYMPTOM
* ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors Failing to Lock From Any Switch
SYMPTOM
* ALL DOORS FAILING TO LOCK FROM ANY SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2420
- Defective unlock switch
All Doors Failing to Lock From One Switch
SYMPTOM
* ALL DOORS FAILING TO LOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors Failing to Unlock From One Switch
SYMPTOM
* ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
Automatic Door Locks Do Not Lock Over 15 MPH
SYMPTOM
* AUTOMATIC DOOR LOCKS DO NOT LOCK OVER 15 MPH
POSSIBLE CAUSES
- Link to body communication bus inoperative
- TPS malfunction causes door lock problem
- VSS malfunction causes door lock problem
- Auto door lock not enabled
Doors Lock With Key In Ignition and Left Door Open
SYMPTOM
* DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN
POSSIBLE CAUSES
- Link to body communication bus inoperative
- BCM defective
- BCM sends wrong key - in ignition status
- BCM a connector terminals damaged
- Ignition switch open
- Key - in ignition switch ground circuit open
- Key - in ignition switch sense circuit open
Driver Door (w/RKE) Failing to Unlock From Any Switch
SYMPTOM
* DRIVER DOOR (W/RKE) FAILING TO UNLOCK FROM ANY SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
One Door Fails to Lock and Unlock From Any Switch
SYMPTOM
* ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2421
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
Remote Keyless Entry Problem
SYMPTOM
* RKE PROBLEM
POSSIBLE CAUSES
- Link to body communication bus inoperative
- RKE circuit at BCM defective
- RKE ground circuit open
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- RKE module default replacement
- RKE module defective
Front Wiper Operating Constantly W/Switch In Off Position
SYMPTOM
* FRONT WIPER OPERATING CONSTANTLY W/SWITCH IN OFF POSITION
POSSIBLE CAUSES
- Front wiper ON/OFF relay control circuit shorted to ground
- Defective wiper ON relay/substitute relay
- Defective multifunction switch/voltage
- High/Low wiper relay HI speed output circuit shorted to voltage
- High/Low wiper relay LO speed output circuit shorted to voltage
- Defective BCM - 100 ohms default
Front Wipers Not Parking In Off Position
SYMPTOM
* FRONT WIPERS NOT PARKING IN OFF POSITION
TEST NOTE
This symptom is diagnosed using the test FRONT WIPER PARK SWITCH CIRCUIT OPEN
POSSIBLE CAUSES
- Wiper park switch toggle closed/open
- Open wiper park switch sense circuit
- Defective BCM - wiper park switch
- Defective wiper motor/wiper park switch
Front Wipers Not Working at All
SYMPTOM
* FRONT WIPERS NOT WORKING AT ALL
POSSIBLE CAUSES
- Open wiper on relay control circuit - BCM/wiper relay
- Defective wiper ON relay - BCM/ground
- Front wiper switch MUX circuit shorted to ground
- Open front wiper switch MUX circuit between switch and BCM
- Defective High/Low wiper relay - relay connector
- Defective multifunction switch/front wiper switch
- High/Low wiper relay HI speed output circuit shorted to ground
- High/Low wiper relay LO speed output circuit shorted to ground
- Open ground circuit/lights
- Open High/Low relay LO speed output circuit between High/Low relay and wiper motor
- Open fused ignition switch output circuit/multifunction switch
- Defective Power Distribution Center - relay connector
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2422
- Defective Power Distribution Center - front wiper relay
- Defective Power Distribution Center - wiper ON relay
- Defective Power Distribution Center - wiper relay
- Defective Power Distribution Center - H/L relay
- Defective Power Distribution Center - B(+) circuit.
- Defective wiper motor/harness
- Defective BCM/wiper relay
- Defective BCM/front wiper MUX
- Defective BCM/sensors
- Defective wiper motor ground circuit.
Front Wipers Not Working In High Speed Mode
SYMPTOM FRONT WIPERS NOT WORKING IN HIGH SPEED MODE
POSSIBLE CAUSES
- Open HI/LO wiper relay control circuit
- Defective HI/LO wiper RELAY - Wiper switch
- Open wiper HI/LO relay HI speed output circuit
- Defective multi - FUNCT switch/ ground circuit
- Defective power DIST CNTR-H/L WPR RLY
- Defective wiper Motor/HI speed output circuit
- Open ground circuit/Multi - Function switch
Front Wipers Not Working In Intermittent Mode
SYMPTOM
* FRONT WIPERS NOT WORKING IN INTERMITTENT MODE
POSSIBLE CAUSES
- Defective multifunction switch/positions
- Defective BCM/wiper positions
- Defective multifunction switch/Default
Front Wipers Not Working In Low Speed Mode
SYMPTOM
* FRONT WIPERS NOT WORKING IN LOW SPEED MODE
POSSIBLE CAUSES
- High/Low wiper relay control circuit shorted to ground
- Defective High/Low wiper relay - fused ignition switch
- Open High/Low wiper relay - LO speed output circuit
- Defective wiper motor/LO speed output circuit
Rear Washer Motor Inoperative
SYMPTOM
* REAR WASHER MOTOR INOPERATIVE
POSSIBLE CAUSES
- Open rear washer motor control circuit
- Defective rear washer motor/jumper
- Open fused ignition switch output circuit/voltage
- Defective HVAC Control Module / 3.8 volts
- Defective BCM - washer motor operate
Rear Wiper Not Parking In the Off Position
SYMPTOM
* REAR WIPER NOT PARKING IN THE OFF POSITION
POSSIBLE CAUSES
- Rear wiper motor control circuit shorted to battery
- Defective HVAC Control Module/switch indicator lights
- Defective wiper motor/wiper motor connector
- Defective BCM/rear wiper motor - default
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2423
- Defective BCM/washer motor run
- Defective BCM/cycle on default
- Defective BCM/rear wiper switch voltage
- Defective rear wiper motor/test light
Rear Wiper Not Working at All
SYMPTOM
* REAR WIPER NOT WORKING AT ALL
POSSIBLE CAUSES
- Open rear wiper motor control circuit
- Open rear wiper switch MUX circuit
- Open ground circuit/rear wiper motor
- Open fused ignition switch output circuit/fuse # 6
- Open fused ignition switch output circuit/fuse # 8
- Shorted fused ignition switch output circuit/fuse # 6
- Defective rear wiper motor/motor control
- Defective HVAC Control Module/default
- Defective HVAC Control Module/rear wiper switch MUX
- Defective BCM/rear wiper switch MUX
- Defective BCM/rear wiper motor
- Defective HVAC Control Module/21-Way connector
Rear Wiper Not Working In the Intermittent Mode
SYMPTOM
* REAR WIPER NOT WORKING IN THE INTERMITTENT MODE
POSSIBLE CAUSES
- Defective rear wiper motor/intermittent switch
- Defective HVAC Control Module/indicator light
- Defective HVAC Control Module/rear wiper switch
- Defective BCM/test light default
Rear Wiper/Wash Working Continuously
SYMPTOM
* REAR WIPER/WASH WORKING CONTINUOUSLY
POSSIBLE CAUSES
- Rear wiper motor control circuit shorted to battery
- Defective wiper motor/wiper motor connector
- Defective BCM/rear wiper motor - default
- Defective BCM/washer motor run
- Defective BCM/rear wiper switch voltage
Wiper/Wash Function Not Working Properly
SYMPTOM
* WIPER/WASH FUNCTION NOT WORKING PROPERLY
POSSIBLE CAUSES
- Defective washer motor/washer pump control
- Operate wipers
- Open washer pump control circuit
- Defective multifunction switch/washer pump control
- Open fused ignition switch output circuit
- Defective junction block/BCM
- Defective junction block/block connector
- Defective BCM/junction block
- Defective BCM/stalk switch
- Fused ignition switch output circuit shorted to ground
- Open washer pump control circuit/multifunction switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2424
Body Control Module: Component Tests and General Diagnostics
Six-Step Troubleshooting Procedure
Diagnosis of the body system is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
Road Testing A Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE
REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN
WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE
IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2425
Body Control Module: Scan Tool Testing and Procedures
Under normal operation, the DRB will display one of only two error messages: - User-Requested
WARM Boot or User-Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the MDS
Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error
message display:
ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD
Boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRB III (R) Does Not Power up (Blank Screen) If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data
link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A.
DRB Scan Tool
Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to
compensate for this condition
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Page 2426
Body Control Module: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove lower steering column cover and
knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control
Module (BCM)
Body Control Module - Location
4. Remove bolts holding Junction Block to dash panel mounting bracket. 5. Remove Junction Block
from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide
Body Control Module downward to disengage guide studs on Junction Block from channels on
BCM mounting bracket. 8. Remove Body Control Module from Junction Block.
INSTALLATION
For installation, reverse the above procedures.
REMOVAL AND INSTALLATION
Refer to Instrument Panel and Systems, Body Control Module Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Page 2427
Body Control Module: Tools and Equipment
DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires
ohmmeter voltmeter oil pressure gauge (0-300 psi) test light
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor ...................................................................................................................
................................................... 14 Nm (125 in. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 2431
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 2432
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 2433
Camshaft Position Sensor: Description and Operation
Camshaft Position Sensor Location
DESCRIPTION
The camshaft position sensor is mounted in the front of the timing case cover.
Camshaft Position Sensor
Camshaft Sprocket
OPERATION
The camshaft position sensor provides cylinder identification to the Powertrain Control Module
(PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass
underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the
pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each
group of camshaft pulses.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 2434
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Ignition Coil Pack
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder
the flat spot and notches identify, they do not indicate TDC position.
CAMSHAFT POSITION SENSOR-PCM INPUT
The PCM determines fuel injection synchronization and cylinder identification from inputs provided
by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM
determines crankshaft position.
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it.
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft
pulses.
The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of
the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel
Injection-Service Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 2435
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 2436
Camshaft Position Sensor: Service and Repair
REMOVAL
Camshaft Position Sensor
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector.
Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt.
Camshaft Sensor Removal/Installation
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 2437
3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the
sensor lead. There is an O-ring on the sensor case. The O-ring may make removal
difficult. A light tap to top of sensor prior to removal may reduce force needed for removal.
INSTALLATION
Camshaft Position Sensor And Spacer
If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If
the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is
positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring
prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor
down until contact is made with the camshaft gear. While holding the sensor in this position, install
and tighten the retaining bolt 14
Nm (125 in. lbs.) torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Temperature Sensor 7 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2441
Coolant Temperature Sensor/Switch (For Computer): Locations
Engine Coolant Temperature Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2442
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2443
Coolant Temperature Sensor/Switch (For Computer): Service Precautions
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT
TEMPERATURE (ECT) SENSOR.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2444
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT
The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40°
F to 265° F).
The engine coolant temperature sensor provides an input voltage to the PCM. As coolant
temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM.
When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The engine coolant sensor is also used for cooling fan control.
Engine Coolant Temperature Sensor
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2445
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Engine Coolant Temperature Sensor
1. With the key off, disconnect wire harness connector from coolant temperature sensor.
Engine Coolant Temperature Sensor
2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter
should read as follows:
a. ECT STET at normal operating temperature around 200°F should read approximately 700 to
1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately
7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater
than 1 ohm, repair the wire harness as necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2446
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT
TEMPERATURE SENSOR.
REMOVAL
1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant
sensor electrical connector. 3. Remove coolant sensor.
INSTALLATION
1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector
to sensor. 3. Fill cooling system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Page 2450
Crankshaft Position Sensor Location
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Page 2451
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Page 2452
Crankshaft Position Sensor: Description and Operation
DESCRIPTION
Crankshaft Position Sensor Location
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing. The bottom of the sensor is positioned next to the drive plate.
OPERATION
Crankshaft Position Sensor
Timing Slots
The crankshaft position sensor detects slots cut into the transmission driveplate extension. There
are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the
position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last
slot,
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Page 2453
it determines crankshaft position (which piston will next be at TDC) from the camshaft position
sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°,
and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
CRANKSHAFT POSITION SENSOR-PCM INPUT
The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3
sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of
the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position
(which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM
one engine revolution to determine crankshaft position.
The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing
and presence of misfire. Once crankshaft position has been determined, the PCM begins
energizing the injectors in sequence.
The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor.
The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of
sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft
position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Page 2454
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Page 2455
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Raise and support vehicle.
Crankshaft Position Sensor Connector
2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3.
Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out
of the trans axle housing.
INSTALLATION
Crankshaft Position Sensor And Spacer
NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the face of the new sensor.
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
Data Link Connector
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions
Data Link Connector: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2461
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2462
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2463
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2464
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2465
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Component Information > Diagrams > Diagram Information and Instructions > Page 2475
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Data Link Connector: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Connector Pin Identification
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Data Link Connector: Description and Operation
Data Link Connector
DATA LINK CONNECTOR-PCM OUTPUT
The data link connector provides the technician with the means to connect the DRB scan tool to
diagnosis the vehicle. The connector is located under the dash.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer
> Component Information > Description and Operation
EGR Backpressure Transducer: Description and Operation
ELECTRONIC EGR TRANSDUCER SOLENOID-PCM OUTPUT
EGR Solenoid
EGR Solenoid
EGR Solenoid
The electronic EGR transducer contains an electrically operated solenoid and a back-pressure
transducer. The PCM operates the solenoid. The PCM determines when to energize the solenoid.
Exhaust system back-pressure controls the transducer.
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> Component Information > Description and Operation > Page 2484
When the PCM energizes the solenoid, vacuum does not reach the transducer. Vacuum flows to
the transducer when the PCM de-energizes the solenoid.
When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the
transducer. When the PCM de-energizes the solenoid and back-pressure closes the transducer
bleed valve, vacuum flows through the transducer to operate the EGR valve.
De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low
back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of
the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount
of exhaust gas recirculation for different operating conditions.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Locations
Powertrain Control Module: Locations
Power Distribution Center & Powertrain Control Module (PCM)
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Powertrain Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Powertrain Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Powertrain Control Module: Connector Views
Powertrain Control Module C1
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Powertrain Control Module C2
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Powertrain Control Module: Description and Operation
OPERATION
Powertrain Control Module
The ignition system is regulated by the Powertrain Control Module (PCM). The PCM supplies
battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM also controls
ground circuit for the ignition coil. By switching the ground path for the coil on and off, the PCM
adjusts ignition timing to meet changing engine operating conditions.
During the crank-start period the PCM advances ignition timing a set amount. During engine
operation, the amount of spark advance provided by the PCM is determined by the following input
factors: available manifold vacuum
- barometric pressure
- engine coolant temperature
- engine RPM
- throttle position
The PCM also regulates the fuel injection system. Refer to the Fuel Injection.
The speed control electronic control circuitry is integrated into the Powertrain Control Module
(PCM). The PCM is located in the engine compartment. The PCM speed control functions are
monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the
PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a
DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be
replaced if faulty.
USE THE DRB SCAN TOOL TO REPROGRAM THE NEW PCM WITH THE VEHICLES
ORIGINAL IDENTIFICATION NUMBER (OIN) AND THE VEHICLES ORIGINAL MILEAGE. IF
THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
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Powertrain Control Module: Service and Repair
REMOVAL
1. Disconnect both cables from battery, negative cable first.
NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after
disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection
Power Distribution Center Retaining Screws
2. Remove 2 screws holding Power Distribution Center (PDC) to bracket.
Battery Heat Shield
3. Remove heat shield from battery.
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Battery Clamp
4. Remove nut and clamp holding battery to battery tray. 5. Remove battery from vehicle.
PDC Rear Bracket
6. Rotate PDC toward center of vehicle to remove from rear bracket. 7. Pull PDC rearward to
remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM).
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PCM 40-way Connectors
8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM. Remove both
way connectors.
PCM Removal/Installation
9. Remove 3 screws holding PCM to fender.
10. Remove PCM from vehicle.
INSTALLATION
1. Connect 2 40-Way electrical connectors to PCM. 2. Install PCM. Tighten mounting screws. 3.
Install PDC bracket. 4. Install battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor >
Component Information > Locations
Fuel Level Sensor: Locations
The level sensor is attached to the side of the fuel pump module.
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Fuel Level Sensor: Description and Operation
DESCRIPTION
The level sensor is attached to the side of the fuel pump module. The level sensor consists of a
float, an arm, and a variable resistor.
OPERATION
As the fuel level increases, the float and arm move up. This decreases the sending unit resistance,
causing the fuel gauge on the instrument panel to read full.
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Fuel Level Sensor: Testing and Inspection
This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit.
Level Sensor Diagnosis
The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the fuel level changes. To test the level sensor,
connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump
module connector. Move the float lever to the positions shown in the resistance chart. Record the
resistance at each point. Replace the level sensor if the resistance is not within specifications.
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Fuel Level Sensor: Service and Repair
REMOVAL
Remove fuel pump module. Refer to Fuel Pump Module.
Fuel Pump/Level Sensor Electrical Connector
1. Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of
the fuel pump module electrical connector.
NOTE: The pump module harness on TOP of flange is not serviceable or removable.
Wire Terminal Locking Wedge
2. Pull off blue locking wedge.
Wire Terminal Locking Finger
3. Using a small screwdriver lift locking finger away from terminal and push terminal out of
connector.
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Removing Wires From Connector
4. Push level sensor signal and ground terminals out of the connector.
Loosening Level Sensor
5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing.
Push level sensor down slightly.
Level Sensor Removal/Installation
6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of
installation channel in module.
INSTALLATION
1. Insert level sensor wires into bottom of opening in module.
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Groove In Back Side Of Level Sensor
2. Wrap wires into groove in back of level sensor.
Installation Channel
3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into
place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector.
Push the wires up through the connector and then pull them down until they lock in place. Ensure
signal and
ground wires are installed in the correct position.
5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module
electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications
Idle Air Control Motor Screws 2 Nm
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Idle Speed/Throttle Actuator - Electronic: Description and Operation
IDLE AIR CONTROL MOTOR-PCM OUTPUT
The idle air control motor is mounted on the throttle body. The PCM operates the idle air control
motor. The PCM adjusts engine idle speed through the idle air control motor to compensate for
engine load or ambient conditions.
The throttle body has an air bypass passage that provides air for the engine at idle (the throttle
blade is closed). The idle air control motor pintle protrudes into the air bypass passage and
regulates air flow through it.
The PCM adjusts engine idle speed by moving the idle air control motor pintle in and out of the
bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the
throttle position sensor, crankshaft position sensor, coolant temperature sensor, and various switch
operations (brake, park/neutral, air conditioning). Deceleration die out is also prevented by
increasing airflow when the throttle is closed quickly after a driving (speed) condition.
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Idle Speed/Throttle Actuator - Electronic: Service and Repair
When servicing throttle body components, always reassemble components with new O-rings and
seals where applicable. Never use lubricants on O-rings or seals, damage may result. If assembly
of component is difficult, use water to aid assembly. Use care when removing hoses to prevent
damage to hose or hose nipple.
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from idle air control
motor.
Servicing Idle Air Control Motor
3. Remove idle air control motor mounting screws. 4. Remove motor from throttle body. Ensure the
O-ring is removed with the motor.
INSTALLATION
1. The new idle air control motor has a new O-ring installed on it. If pintle measures more than 1
inch (25 mm) it must be retracted. Use the DRB
Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected.)
2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten
screws to 2 Nm (17 in. lbs.) torque. 4. Connect electrical connector to idle air control motor. 5.
Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Information Bus: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Vehicle Communication
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Information Bus: Description and Operation
VEHICLE COMMUNICATION
The body system consists of a combination of modules that communicate over the CCD (Chrysler
Collision Detection multiplex system) bus. Through the CCD bus, information about the operation
of vehicle components and circuits is relayed to the appropriate module(s). Each module receives
the same information about a component or circuit as the other modules do. This significantly
reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system called "bus + " (bus plus)
and "bus - " (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5
volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the
coded messages, there is a "voltage divider network". This network consists of some modules with
bias and some with termination. Bias is the part of the voltage divider network that places both bus
(+) and bus (-) at 2.5 volts.Termination in the circuitry is required to complete the voltage divider
network and also provides some electromagnetic protection for the bus.
NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF
THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE
OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH
DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE
COMMUNICATIONS.
Any of the following bus failure messages may be displayed.
Short to Battery - Either or both of the bus wires are shorted to the battery potential.
Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential.
Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be
open.
Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together.
No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts.
Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their
normal 2.5 volts.
No Bus Bias - The bus system has lost connection with all modules that provide bias.
Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias.
Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not
know why.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations
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Knock Sensor
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Knock Sensor: Description and Operation
Knock Sensor
KNOCK SENSOR-PCM INPUT
The knock sensor is only on these engines.
The knock sensor threads into the side of the cylinder block in front of the starter. When the knock
sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response,
the PCM retards ignition timing for all cylinders by a scheduled amount.
Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM.
As the intensity of the engine knock vibration increases, the knock sensor output voltage also
increases.
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Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: ignition timing,
cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude
increases with the increase of engine knock. The knock sensor can be tested with a digital
voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to
approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set.
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Knock Sensor: Service and Repair
Knock Sensor
The knock sensor threads into the side of the cylinder block in front of the starter.
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening
effects knock sensor performance, possibly
causing improper spark control.
2. Attach electrical connector to knock sensor.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Battery Negative Cable
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Power Distribution Center -- Sheet 8w-10-2
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Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Instructions > Page 2572
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 2580
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Instructions > Page 2581
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Automatic Shut Down (ASD) Relay: Connector Views
Power Distribution Center
Automatic Shut Down Relay
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Automatic Shut Down (ASD) Relay: Description and Operation
Power Distribution Center
DESCRIPTION
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and
fuses in the PDC.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02
Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM
monitors the crankshaft position sensor and camshaft position sensor signals to determine engine
speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor
and camshaft position sensor signals when the ignition switch is in the Run position, it will
de-energize the ASD relay.
AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT
OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt
signal at this input indicates to the PCM that the ASD has been activated. This input is used only to
sense that the ASD relay is energized.
When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC).
AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT
The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic
ignition coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and
contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss
bar in the PDC and the relay. The fuse is located in the PDC.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2
Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the
On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position
sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not
receive the crankshaft position sensor and camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the ASD relay.
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Power Distribution Center
The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies
the relays and fuses in the PDC.
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(ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
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(ASD) Relay > Page 2589
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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Automatic Shut Down (ASD) Relay: Service and Repair
The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover
has a label showing relay and fuse location.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR (CHECK ENGINE) LAMP-PCM OUTPUT
The PCM supplies the malfunction indicator (check engine) lamp on/off signal to the instrument
panel through the CCD Bus. The CCD Bus is a communications port. Various modules use the
CCD Bus to exchange information.
The Check Engine lamp comes on each time the ignition key is turned ON and stays on for 3
seconds as a bulb test.
The Malfunction Indicator Lamp (MIL) stays on continuously, when the PCM has entered a Limp-In
mode or identified a failed emission component. During Limp-in Mode, the PCM attempts to keep
the system operational. The MIL signals the need for immediate service. In limp-in mode, the PCM
compensates for the failure of certain components that send incorrect signals. The PCM substitutes
for the incorrect signals with inputs from other sensors.
If the PCM detects active engine misfire severe enough to cause catalyst damage, it flashes the
MIL.
At the same time the PCM also sets a Diagnostic Trouble Code (DTC). For signals that can trigger
the MIL (Check Engine Lamp) refer to the On-Board Diagnostics Chart.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
Sensor Tightening Torque 35 in.lb
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MAP Sensor
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Sensor > Component Information > Specifications > Page 2599
Manifold Pressure/Vacuum Sensor: Description and Operation
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT
The PCM supplies 5 volts to the MAP sensor. The MAP sensor converts intake manifold pressure
into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP
sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage
increases proportionately.
During cranking, before the engine starts running, the PCM determines atmospheric air pressure
from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold
pressure from the MAP sensor voltage.
Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and
the air/fuel mixture.
MAP Sensor
MAP Sensor
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Sensor > Component Information > Specifications > Page 2600
MAP Sensor
The MAP sensor mounts to the intake manifold near the throttle body inlet to the manifold. The
sensor connects electrically to the PCM.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications > Page 2601
Manifold Pressure/Vacuum Sensor: Testing and Inspection
To perform a complete test of the MAP sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following:
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
MAP Sensor Connector
1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3.
With the ignition switch ON and the engine not
running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot,
neutral idle speed condition. If OK, go to next step. If not OK, go to step 3.
2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness
condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1
and PCM terminal 43. If OK, go to next step. If not OK, repair as required. 4. Test MAP sensor
supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should
be approximately 5 volts (±
0.5V). Five volts ± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. If
not OK, repair or replace the wire harness as required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications > Page 2602
Manifold Pressure/Vacuum Sensor: Service and Repair
Map Absolute Pressure Sensor
REMOVAL
1. Disconnect electrical connector from MAP sensor. 2. Remove two screws holding sensor to the
intake manifold.
INSTALLATION
1. Reverse the above procedure for installation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Specifications
Oxygen Sensor: Specifications
Upstream and Downstream Oxygen Sensor 27 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Oxygen Sensor Bank Locations
Oxygen Sensor: Locations Oxygen Sensor Bank Locations
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Oxygen Sensor Bank Locations > Page 2608
Oxygen Sensor: Locations Oxygen Sensor(s)
Heated Oxygen Sensor
Downstream Heated Oxygen Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Page 2609
Oxygen Sensor: Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Page 2610
Oxygen Sensor: Service Precautions
WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN
SERVICING THE OXYGEN SENSOR
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Page 2611
Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Page 2612
Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (O2S SENSOR)-PCM INPUT
The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas
in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel
mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel
mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to
electrical voltage, the sensors act as a rich-lean switch.
The oxygen sensors are equipped with a heating element that keeps the sensors at proper
operating temperature during all operating modes. Maintaining correct sensor temperature at all
times allows the system to enter into closed loop operation sooner. Also, it allows the system to
remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM
monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly.
During Open Loop operation the PCM ignores the 02 sensor input. The PCM adjusts injector pulse
width based on preprogrammed (fixed) values and inputs from other sensors.
The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and
downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element.
The heating elements reduce the time required for the sensors to reach operating temperature.
UPSTREAM HEATED OXYGEN SENSOR
Heated Oxygen Sensor
Heated Oxygen Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Page 2613
Heated Oxygen Sensor
The upstream O2S is located in the exhaust manifold and provides an input voltage to the PCM.
The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to
fine tune the air/fuel ratio by adjusting injector pulse width.
DOWNSTREAM HEATED OXYGEN SENSOR
Downstream Heated Oxygen Sensor
The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic
convertor. The downstream heated oxygen sensor input is used to detect catalytic convertor
deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match
the upstream sensor input except for a slight time delay. By comparing the downstream heated
oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor
efficiency.
When the catalytic converter efficiency drops below emission standards, the PCM stores a
diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information,
refer to Emission Control Systems.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Page 2614
Oxygen Sensor: Testing and Inspection
Use an ohmmeter to test the heating element of the oxygen sensors. Disconnect the electrical
connector from each oxygen sensor. The white wires in the sensor connector are the power and
ground circuits for the heater. Connect the ohmmeter test leads to terminals of the white wires in
the heated oxygen sensor connector. Replace the heated oxygen sensor if the resistance is not
between 4 and 7 ohms.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Downstream Oxygen Sensor Replacement
Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement
REMOVAL
1. Raise and support vehicle.
WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN
SERVICING THE OXYGEN SENSOR.
Oxygen Sensor Grommet Cover
2. Remove grommet cover to expose connector.
Oxygen Sensor Connector Locking Tab
3. Push locking tab back and unplug oxygen sensor electrical connector.
Oxygen Sensor Removal/Installation
4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 5. When the sensor is
removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using
original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 2617
INSTALLATION
1. Reverse removal procedure to install a new sensor.
New sensors are packaged with compound on the threads and no additional compound is required.
The sensor must be tightened to 27 Nm (20 ft. lbs.) torque.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 2618
Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement
Upstream Heated Oxygen Sensor
The oxygen sensor is installed in the exhaust manifold .
CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector.
WARNING: THE EXHAUST MANIFOLD AND CATALYTIC CONVERTER MAY BE EXTREMELY
HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR.
REMOVAL
1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such
as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust
manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
New sensors are packaged with compound on the threads and no additional compound is required.
The sensor must be tightened to 27 Nm (20 ft. lbs.) torque.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical
- Wiring Schematics Revisions
Body Control Module: Technical Service Bulletins Electrical - Wiring Schematics Revisions
NUMBER: 26-12-99G
GROUP: Miscellaneous
DATE: December, 1999
THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revisions to the wiring schematics
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- Wiring Schematics Revisions > Page 2624
8W-44-5
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- Wiring Schematics Revisions > Page 2625
8W-44-7
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- Wiring Schematics Revisions > Page 2626
8W-45-7
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- Wiring Schematics Revisions > Page 2627
8W-50-2
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- Wiring Schematics Revisions > Page 2628
8W-50-5
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- Wiring Schematics Revisions > Page 2629
8W-50-7
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- Wiring Schematics Revisions > Page 2630
8W-80-15
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- Wiring Schematics Revisions > Page 2631
8W-90-3
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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- Wiring Schematics Revisions > Page 2632
8W-90-11
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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- Wiring Schematics Revisions > Page 2633
Body Control Module: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out
Revisions
NUMBER: 26-04-99
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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- Wiring Schematics Revisions > Page 2634
8N-4
Revision to the Body Control Module connector pin-out
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical
- Wiring Schematics Revisions > Page 2635
8W-80-13
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical
- Wiring Schematics Revisions > Page 2636
Body Control Module: Technical Service Bulletins Body Control Module - Erroneous DTC Set
NO: 18-25-98
GROUP: Vehicle Performance
DATE: Aug. 14, 1998
SUBJECT: Erroneous Body Control Module Diagnostic Trouble Code
MODELS:
1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSAXLE.
DISCUSSION:
During service diagnostic procedures, the Body Control Module (BCM) may indicate an erroneous
"EATX PRNDL NOT RECEIVED" Diagnostic Trouble Code (DTC). If this DTC exists, turn the
ignition to the ON position and determine if each PRNDL indicator in the instrument cluster
becomes boxed (all boxed at the same time) after ten seconds. If all PRNDL indicators do NOT
become boxed at the same time, the DTC is erroneous and the DTC should be cleared, it is not
necessary to replace the BCM.
NOTE:
CHRYSLER HAS NOT RECEIVED ANY REPORTS OF THIS DTC BEING SET BY AN ACTUAL
FAILURE IN THE PRNDL SYSTEM.
POLICY: Information Only
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Electrical
- Wiring Schematics Revisions > Page 2637
Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics
NO: 08-40-98
GROUP: Electrical
DATE: Sept. 25, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED
DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL
VEHICLES.
MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager
DISCUSSION:
During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp
Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head
lamps.
If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at
erasing this erroneous DTC will be unsuccessful.
If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan,
Voyager and Town & Country Body Diagnostic Procedures Manual.**
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations
Body Control Module: Component Locations
Body Control Module
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Page 2640
Junction Block, Body Control Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Body Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 2643
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 2644
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 2645
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Instructions > Page 2646
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Instructions > Page 2647
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Instructions > Page 2648
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Instructions > Page 2649
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Instructions > Page 2650
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Body Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Body Control Module: Connector Views
Body Control Module C1 (A)
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Body Control Module C2 (B)
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Junction Block
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Body Control Module Interconnect
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Body Control Module: Electrical Diagrams
BCM Block Diagram
Wiring Diagrams
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Body Control Module -- Sheet 8w-45-2
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Body Control Module -- Sheet 8w-45-3
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Body Control Module -- Sheet 8w-45-4
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Body Control Module -- Sheet 8w-45-5
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Body Control Module -- Sheet 8w-45-6
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Body Control Module -- Sheet 8w-45-7
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Body Control Module -- Sheet 8w-45-8
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Body Control Module -- Sheet 8w-45-9
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
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Body Control Module: Service Precautions
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
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3
Body Control Module: Description and Operation Part 1 of 3
INTRODUCTION
Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION
AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger
protection if the vehicle is involved in a front end collision. The system is most effective when used
in conjunction with the seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. This information will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
Functional Operation Whenever the ignition key is turned to the "run" or "start" position, the airbag
control module (ACM) performs a lamp check by turning the AIRBAG warning lamp ON. The lamp
stays lit for 6 to 8 seconds, then goes off. If the lamp remains OFF, it means that the ACM has
checked the system and found it to be free of discernible malfunctions. The airbag system is
monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures in this book to find the cause of any customer complaint regarding the
AIRBAG warning lamp, such as: warning lamp does not come on at all
- warning lamp stays on
BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with
visual and audible information and controls various vehicle functions. To provide and receive
information, the module is interfaced to the vehicle's serial bus communications network (the
Chrysler Collision Detection bus, or CCD bus). This network consists of the powertrain control
module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster
(MIC), the airbag control module (ACM), the compass/mini- trip module and the controller antilock
brake (CAB) module. The BCM is operational when battery power is supplied to the module.
Ignition switch power is needed for ignition switch functions.
The body control module provides the following features: automatic door locks
- battery protection
- CCD radio
- chimes
- compass/mini-trip support
- courtesy lamps
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
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- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid
wearing down the battery if the customer leaves the parklamps or headlamps on for extended
periods of time with the ignition OFF. If the parklamp or headlamp switch remains in the active
position for more than 3 minutes, while the ignition is OFF, the parklamps and or headlamps will be
turned off and the input causing the lamps to be ON will be ignored. Once the 3 minute time-out has
elapsed the BCM will enter sleep mode. Any change in any inputs monitored by the BCM that
brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock), door ajar,
ignition, RKE actuation, etc.).
Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory
power ON) will inhibit the battery protection routine from turning OFF the exterior lamps as
described above.
Battery Protect: "Reading & Glove Box Lamps" This feature provides a battery protection scheme to
avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity
mirrors ON. The BCM provides a ground circuit for these interior lamps. This ground path is
connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters
sleep mode. Once the 15 minutes time-out has expired, any monitored input that brings the BCM
out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central
Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and
vanity mirrors to normal operation (normal operation defined as: "ON" is reading lamp and visor
vanity mirrors ON, or glove box open; "OFF" if reading lamp and visor vanity mirrors OFF, and
glove box closed).
Leaving the keys in the ignition switch, while the ignition is OFF, will not inhibit the battery
protection from turning off these interior lamps as described above. Leaving the ignition switch in
an active position (steering column unlocked, ignition ON or accessory power on) will inhibit the
battery protection routine from turning off these interior lamps as described above.
Shipping Mode By definition, shipping mode is when the IOD fuse is removed from the vehicle. The
BCM receives its primary power feed from the battery via the IOD fuse. The BCM also receives a
back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry,
courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is
reconnected or the ignition switch is turned to the run/start position.
Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which
are controlled by the body controller module (BCM). When the parklamp switch is closed to ground
the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same
parklamp power feed is also wired back into the BCM to provide the power feed for the PWM
circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and
high beam headlamp relays. The position of the hi-beam select switch will determine the mode of
operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and
low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of
operation at a time.
Auto Headlamps On vehicles equipped with the auto headlamp feature, the BCM will control the
exterior lamp operation by monitoring the mode selection switch located in the headlamp control
panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the
Electro-Chromic Rear View mirror. The mirror will determine the appropriate ambient light levels for
turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to
darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see
Headlamp Delay Feature description).
Headlamp Time Delay The headlamp Delay feature keeps the Headlamps on for 60 seconds giving
the driver and passengers security lighting when exiting the vehicle. This feature is only available
on vehicles equipped with RKE. The Headlamp Delay feature is activated by sequentially turning
off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be
turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45
second window is new for the NS body Once the headlamp delay has been activated the
headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the
ignition switch changes states.
CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and
announcement. Warning chimes are provided for dome lamps on, engine temperature lamp,
exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above
15 mph). The warning chime will sound continuously until the condition is removed or the battery
protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for
approximately six seconds or until the seat belt is fastened, The announcement chime will sound
one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar
lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the
vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the
instrument cluster warning lamp diagnostics.
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Body Control Module: Description and Operation Part 2 of 3
COMPASS/MINI-TRIP COMPUTER
The compass/mini-trip computer is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE),
instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information
needed for the traveler functions is received over the CCD bus from the body control module.
If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration.
Setting The Compass The compass/mini-trip module is self-calibrated and requires no adjustment.
The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL
will turn off after the vehicle has gone in three complete circles without stopping, in an area free of
magnetic disturbance.
If the module displays the temperature while the compass is blank or shows a false reading, the
vehicle must be demagnetized. See the service procedure.
If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module
must be replaced.
Compass Magnetic Variance Zones
Setting The Variance Variance is the difference between magnetic north and geographic north. To
determine the variance for the area you are in, refer to the following zone map provided. The
number shown for your area is the variance number for your area. 1. Set the compass/mini-trip
console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5
seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the
variance to 8 and enter the fast calibration mode.
3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP
button to set the zone number. 5. Press the US/M button and resume normal operation,
NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO
THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS.
MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular
position of the gauges, the status of all CCD indicator lamps, the status and dimming of the
mechanical instrument cluster (MIC) over the CCD bus when the ignition is in the "off,, (unlock),
"run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the
ignition is in the "OFF" (unlock), "run", or "start" positions; all other MIC features work only when
ignition is in the "run position. On transition of the ignition from the "OF"' to the "run" position, a bulb
check is performed. This consists of activating all CCD controlled indicator lamps and all VF display
segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is
moved from the PARK position, or if the engine exceeds 450 rpm.
POWER DOOR LOCK SYSTEM When the BCM receives an input for a lock request (door lock
switch, RKE, or door key cylinder switch (only with VTSS)), it will ground the lock-relay coil for a
specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1
second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door
lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The
unlock signal operates in the same fashion as the lock signal. The door Lock switches provide a
variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the
BCM will respond to that command.
Other power Door Lock features: Sliding Door Memory Lock- When the BCM receives an input for
a lock request and a sliding door is open, the BCM will turn on the lock relay
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as described above, and will turn it on again when all sliding doors are closed.NOTE: If the BCM
receives an unlock input before a sliding door is closed this action will cancel the memory lock.
Door Lock Inhibit- When the key is in the ignition and in the off position, and any door except the
rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional.
This protects against locking the vehicle with the keys still in the ignition.
Automatic Door Locks- This feature can be enabled or disabled by using either the DRBIII or
customer programming method. When enabled, all the doors will lock when the vehicle reaches a
speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15
MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH.
RKE (Remote Keyless Entry) Interface- The body control module interfaces with the RKE receiver
via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the
BCM depending on which button on the transmitter was pressed. The BCM controls the door
lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The
RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the
PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the
RKE.
The RKE module can be programmed via the DRBIII or customer programming method. The BCM
will only allow programming mode to be entered when the ignition is in the ON position, the PRNDL
is in park position, and the VTSS (if equipped) is in the disarmed mode.
Programming an RKE Transmitter
Customer Programming Method
NOTE: A VALID, PREVIOUSLY PROGRAMMED TRANSMITTER MUST BE USED.
1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition on, place the transmission
in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3.
Using the previously programmed transmitter, press and hold the unlock button for 4 to 8 seconds.
While still holding the unlock button, press the panic button, then release both buttons. The BCM
will acknowledge that it has grounded the RKE module program enable wire by sounding a single
chime tone.
4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has
accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle
(up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode
sooner, turn the ignition off.
DRB Programming 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition ON,
place the transmission in park, and make sure the vehicle theft security system (if equipped) is in
disarm mode. 3. Select Program RKE" under "Miscellaneous". If the message "BCM is in
Programming Mode" does not appear, exit and select "Program
RKE" again.
4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has
accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle
(up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode
sooner, press "Back Page".
RADIO SYSTEM There are three radio systems available this year that will be on the CCD bus.
They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the
radio remote controls in the steering wheel. They can control volume up/ down, seek up, seek
down and preset station selections. These systems also communicate with the body control
module and will set a specific code if there is a problem with the remote controls.
The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of
the 4 main quarter speakers have a built in amplifier. The I/P and pillar speakers receive their
signals from the quarter speakers. Depending on the manufacture some systems will have a
Front/Rear channel system and others will have a Left/Right channel system. If one of the main
quarter speaker audio circuits experiences a short, the other speakers on that channel will also
shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible
with the DRB, indicating which channel is effected.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Part 1 of
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Body Control Module: Description and Operation Part 3 of 3
VEHICLE COMMUNICATION The body system consists of a combination of modules that
communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD
bus, information about the operation of vehicle components and circuits is relayed to the
appropriate module(s). Each module receives the same information about a component or circuit
as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and
the size of the wiring harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system called "bus +" (bus plus)
and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts.
In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded
messages, there is a "voltage divider network". This network consists of some modules with bias
and some with termination. Bias is the part of the voltage divider network that places both bus +
and bus - at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network
and also provides some electromagnetic protection for the bus.
NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF
THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE
OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH
DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE
COMMUNICATIONS.
Any of the following bus failure messages may be displayed. Short to Battery- Either or both of the
bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are
shorted to a 5-volt potential. Short to Ground- Either or both of the bus wires are shorted to ground
or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are
shorted together. No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly
above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules
that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus
Messages Correctly - The DRB cannot communicate over the bus and does not know why.
VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against theft.
The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle
hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the
horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an
engine "no run" feature.
Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's
door, locking the doors with the power lock, and closing the driver's door or locking the doors with
RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator
lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no
monitored systems are activated during this period, the system Will arm. If the hood ajar switch is
seen as closed circuit by the system, the indicator lamp Will remain steadily lit during the arming
process, although the system will still arm.
When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for
about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate
is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override The system will not arm if the doors are locked using the manual lock control (by hand) or if the
locks are actuated by an inside occupant after the door is closed.
When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus
to the powertrain control module that it is not OK to start the engine. The powertrain control module
then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting
down the engine (start and stall condition). The engine will not start until the system is disarmed.
To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but
keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE:
After the doors are closed, locking the doors with RKE will also arm the system.
NOTE: IF THE VTSS INDICATOR LAMP FLASHED, THE SYSTEM IS OPERATIONAL AND
VERIFIED. IF NOT, THERE MAY BE A PROBLEM WITH THE SYSTEM.
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System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is
closed. 1. Rotating the key in liftgate cylinder to unlock/disarm position.
Arming/Disarming- Active arming occurs when the remote keyless entry transmitter is used to lock
the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming
sequence is completed only after all door are closed.
Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with
the key). This disarming also will halt the alarm once it has been activated.
Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle
doors. This disarming also will halt the alarm once it has been activated.
System Self-Test - NOTE: System self-test can be entered only with the DRB.
NOTE: A POWERTRAIN CONTROL MODULE FROM A VEHICLE EQUIPPED WITH A VEHICLE
THEFT SECURITY SYSTEM CANNOT BE USED IN A VEHICLE THAT IS NOT EQUIPPED WITH
A VEHICLE THEFT SECURITY SYSTEM.
If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication
with the powertrain control module possibly has been lost.
WIPER SYSTEM
Front The front wiper system provide the driver with normal wipe (low and high speeds),
intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function
via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the
on position and the ignition is turned OFF the wiper will continue to run until it reaches its park
position.
Other front wiper system features: Speed Sensitive Intermittent Wipe Mode- There are 6 individual
delay times with minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle
speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36
seconds.
Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more
than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided.
Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then
releases it, the wiper will continue to run for 2 additional wipe cycles.
Rear The rear wiper system provides the driver with continuous, intermittent, and wiper after wash
functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the
HVAC control.
DRB III (R) ERROR MESSAGES
Under normal operation, the DRB will display one of only two error messages: - User-Requested
WARM Boot or User- Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the MDS
Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error
message display:
ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD
Boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRB III (R) Does Not Power UP (Blank Screen) If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data
link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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DRB Scan Tool
Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to
compensate for this condition
WARNINGS
Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is
"OFF". Failure to do so could damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair
verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or
symptom condition.
CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE
REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN
WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE
IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB.
REQUIRED TOOLS AND EQUIPMENT
DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires
ohmmeter voltmeter oil pressure gauge (0-300 psi) test light
GLOSSARY OF ACRONYMS
ACM Airbag Control Module
AECM Airbag Electronic Control Module (type of ACM)
ASDM Airbag System Diagnostic Module (type of ACM)
BCM body control module
CAB controller antilock brake
CCD Chrysler Collision Detection (vehicle communications bus)
CMTC
Compass/Mini-Trip Computer (module)
DLC data link connector (previously called "engine diagnostic connector")
DR driver
HVAC heater, ventilation, air condition
MET metric
MIC mechanical instrument cluster
MUX multiplexed
ODO odometer
PASS passenger
PCM powertrain control module
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PDC powertrain distribution center
PTC positive temperature coefficient
RKE remote keyless entry
TCM transmission control module
VF vacuum fluorescent display
VTSS
vehicle theft security system
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures
Body Control Module: Symptom Related Diagnostic Procedures
AM/FM Switch Inoperative
SYMPTOM
* AM/FM SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Balance Joystick Inoperative
SYMPTOM
* BALANCE JOYSTICK INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Cassette Error
SYMPTOM
CASSETTE ERROR
POSSIBLE CAUSES
- Cassette Error / Replace radio
CD Eject Switch Inoperative
SYMPTOM
* CD EJECT SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
CD Error
SYMPTOM
CD ERROR
POSSIBLE CAUSES
- Defective radio
Equalizer Inoperative
SYMPTOM
* EQUALIZER INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
External CD Changer (If Equipped)
SYMPTOM
* EXTERNAL CD CHANGER (IF EQUIPPED)
POSSIBLE CAUSES
- Radio/CD cable loose/disconnected
- DIN cable data bus (CAV 1) open
- DIN cable data bus (CAV 3) open
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Related Diagnostic Procedures > Page 2686
- DIN cable terminals shorted
- DIN signal wires (CAVS 2, 4, and 5) open
- DIN fused B(+) circuit open
- DIN fused ignition switch output circuit open
- DIN ground circuit open
- DIN metal connectors open
- Radio defective
- Radio input control defective
FF/RW Switch Inoperative
SYMPTOM
* FF/RW SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Hour/Minute Switch Inoperative
SYMPTOM
* HOUR/MINUTE SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
No Sound From All Speakers
SYMPTOM
* NO SOUND FROM ALL SPEAKERS
POSSIBLE CAUSES
- Radio 12V output circuit defective, open
- Radio ground circuit defective, open
- Power relay output circuit defective, open
- Radio 12V output circuit shorted to ground
- Radio choke defective
- Speaker power relay defective, open
- Speaker power relay defective, open
- Junction block defective, open circuit
- Defective radio
- Radio choke output circuit defective, open
- Radio output circuits defective
No Sound From One Speaker
SYMPTOM
* NO SOUND FROM ONE SPEAKER
POSSIBLE CAUSES
- Door or quarter speaker (+) circuit defective, open
- Door or quarter speaker (-) circuit defective, open
- Door or quarter speaker (+) circuit open
- Door or quarter speaker (-) circuit open
- Instrument panel or pillar speaker (+) circuit open
- Instrument panel or pillar speaker (-) circuit open
- Door or quarter speaker defective
- Speaker defective, no response
Pause/Play Switch Inoperative
SYMPTOM
* PAUSE/PLAY SWITCH INOPERATIVE
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2687
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Poor Sound Quality All Speakers
SYMPTOM
* POOR SOUND QUALITY ALL SPEAKERS
POSSIBLE CAUSES
- Antenna connector defective
- Antenna connections defective
- Hood ground defective
- Ground circuit defective, open
- Radio connectors not properly connected
- Ignition / alternator system noise
- Radio defective
Poor Sound Quality From One Speaker
SYMPTOM
* POOR SOUND QUALITY FROM ONE SPEAKER
POSSIBLE CAUSES
- Ground circuit open
- Instrument panel - pillar speaker defective
- Radio choke output circuit open
- Speaker (+) and (-) circuits shorted together
- Inoperative speaker defective
PWR Switch Inoperative
SYMPTOM
* PWR SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Radio Error
SYMPTOM
RADIO ERROR
POSSIBLE CAUSES
- Defective radio
Remote Controls Inoperative
SYMPTOM
* REMOTE CONTROLS INOPERATIVE
POSSIBLE CAUSES
- No response, CCD bus failure
- Radio control harness defective, open
- Radio control MUX circuit shorted
- Remote control switch defective
- MUX control clockspring defective
- Radio control ground circuit to BCM open
- Radio control MUX circuit open
- Radio MUX control circuit defective
- Body Control Module defective
Scan Switch Inoperative
SYMPTOM
* SCAN SWITCH INOPERATIVE
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2688
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Seek Switch Inoperative
SYMPTOM
* SEEK SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Set Switch Inoperative
SYMPTOM
* SET SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Shorted Front Channel
SYMPTOM
SHORTED FRONT CHANNEL
POSSIBLE CAUSES
- Left door speaker shorted
- Left front instrument panel speaker shorted
- Right door speaker shorted
- Right front instrument panel speaker shorted
- Right front (-) circuit shorted to ground
- Right front (+) and (-) circuits shorted together
- Right front (+) circuit shorted to ground
- Left front (+) and (-) circuits shorted together
- Left front (+) circuit shorted to ground
- Left front (-) circuit shorted to ground
- Radio output circuits defective
Shorted Left Channel
SYMPTOM
SHORTED LEFT CHANNEL
POSSIBLE CAUSES
- Left door speaker defective, shorted
- Left front instrument panel speaker defective, shorted
- Left quarter speaker shorted
- Left rear (+) and (-) circuits shorted together
- Left rear (+) circuit shorted to ground
- Left rear (-) circuit shorted to ground
- Left rear speaker shorted
- Left front (+) and (-) circuits shorted together
- Left front (+) circuit shorted to ground
- Left front (-) circuit shorted to ground
- Radio output circuits defective
Shorted Rear Channel
SYMPTOM
SHORTED REAR CHANNEL
POSSIBLE CAUSES
- Right rear quarter speaker shorted
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Related Diagnostic Procedures > Page 2689
- Left rear (+) and (-) circuits shorted together
- Left rear (+) circuit shorted to ground
- Left rear (-) circuit shorted to ground
- Left rear quarter speaker shorted
- Left rear speaker shorted
- Right rear (+) and (-) circuits shorted together
- Right rear (+) circuit shorted to ground
- Right rear (-) circuit shorted to ground
- Right rear pillar speaker shorted
- Radio output circuits defective
Shorted Right Channel
SYMPTOM
SHORTED RIGHT CHANNEL
POSSIBLE CAUSES
- Right channel speaker shorted
- Right instrument panel speaker defective, shorted
- Right front (+) circuit shorted to ground
- Right front (+) and (-) circuits shorted together
- Right front (-) circuit shorted to ground
- Right pillar speaker shorted
- Right quarter speaker shorted
- Right rear (+) and (-) circuits shorted together
- Right rear (+) circuit shorted to ground
- Right rear (-) circuit shorted to ground
- Radio output circuits defective
Tape Eject Switch Inoperative
SYMPTOM
* TAPE EJECT SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Tune Switch Inoperative
SYMPTOM
* TUNE SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Volume/Time Switch Inoperative
SYMPTOM
* VOL/TIME SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
1-5 Presets Inoperative
SYMPTOM
* 1-5 PRESETS INOPERATIVE
POSSIBLE CAUSES
- Radio function controls inoperative
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Related Diagnostic Procedures > Page 2690
Chime Inoperative at All Times
SYMPTOM
* CHIME INOPERATIVE AT ALL TIMES
POSSIBLE CAUSES
- BCM fails chime test
Chime Inoperative With Driver Seat Belt Unfastened
SYMPTOM
* CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED
POSSIBLE CAUSES
- Ground circuit to left seat belt switch connector open
- Left seat belt switch open
- BCM not responding to belt switch
- Body Control Module seat belt switch sense open
- Seat belt switch sense circuit open
Chime Inoperative With Engine Temperature Critical
SYMPTOM
* CHIME INOPERATIVE WITH ENGINE TEMPERATURE CRITICAL
POSSIBLE CAUSES
- BCM - No response to oil pressure
- BCM fails chime test
Chime Inoperative With Exterior Lamps On
SYMPTOM
* CHIME INOPERATIVE WITH EXTERIOR LAMPS ON
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition Switch - key in switch shorted
- BCM - no chime response - head/park lamps ON
- BCM - key in sense shorted default
- BCM - no response to park lamp switch
- Chime inoperative with exterior lamps ON
Chime Inoperative With Key In Ignition & Driver Door Open
SYMPTOM
* CHIME INOPERATIVE WITH KEY IN IGNITION & DRIVER DOOR OPEN
POSSIBLE CAUSES
- Ignition switch ground circuit open
- Key in ignition switch sense circuit open
- Ignition switch - key in switch open
- BCM - no chime to key in ignition
- BCM not responding to key in switch
Chime Inoperative With L or R Turn Signal On For 1 Mile
SYMPTOM
* CHIME INOPERATIVE WITH LEFT OR RIGHT TURN SIGNAL ON FOR 1 MILE
POSSIBLE CAUSES
- Junction block - Left turn signal open
- Junction block - Right turn signal open
- BCM - no response to turn signal
- BCM fails speed test
- Chime - speedometer problem
- Chime inoperative - turn signal on for 1 mile
Chime Inoperative With Low Oil Pressure
SYMPTOM
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2691
* CHIME INOPERATIVE WITH LOW OIL PRESSURE
POSSIBLE CAUSES
- BCM - No response to oil pressure
- BCM fails chime test
Chime Inoperative With the Dome Lamps On
SYMPTOM
* CHIME INOPERATIVE WITH THE DOME LAMPS ON
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition switch - key in switch shorted
- BCM failed - door open & key out default
- BCM - key in switch sense shorted default
Chime Sounds With Driver Door Open & Key Out
SYMPTOM
* CHIME SOUNDS WITH DRIVER DOOR OPEN & KEY OUT
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition switch - key in switch shorted
- BCM - key in switch sense shorted default
- BCM not responding to key out
Chime Sounds With Driver Seat Belt Fastened
SYMPTOM
* CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED
POSSIBLE CAUSES
- Seat belt switch sense circuit shorted to ground
- Left seat belt switch shorted
- BCM - no response to seat belt fastened
- BCM seat belt switch input shorted to ground
Auto Headlamps Will Not Turn Off
SYMPTOM
* AUTO HEADLAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- No response (PCM) - CCD bus failure
- Auto headlamp signal circuit open
- Auto headlamp signal circuit shorted to ground
- Electrochromic mirror defective - sensor stuck ON (default)
- BCM defective - auto headlamp sensor stuck ON
Auto Headlamps Will Not Turn On
SYMPTOM
* AUTO HEADLAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- NO response (BCM) - CCD bus failure
- NO response (PCM) - CCD bus failure
- Auto headlamp signal circuit open
- Electrochromic mirror defective (default)
- BCM defective - auto headlamp sensor
Fog Lamps Will Not Turn Off
SYMPTOM
* FOG LAMPS WILL NOT TURN OFF
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2692
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Fog lamp switched ground circuit shorted to ground
- Headlamp switch defective - foglamp switched ground
Fog Lamps Will Not Turn On
SYMPTOM
* FOG LAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Fog lamp bulbs open
- Fog lamp relay control circuit open
- Fog lamp relay output circuit open
- Fog lamp relay defective, open
- Multifunction dimmer switch defective (open) default
- Fog lamp switched ground circuit open
- BCM defective - Headlamp relay control
- Multifunction switch defective (fog lamp relay control) default
- Headlamp relay control circuit (foglamps) open
Headlamps Will Not Turn Off
SYMPTOM
* HEADLAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch sense circuit shorted to ground
- Headlamp relay control circuit shorted to ground
- Low beam relay control circuit shorted to ground
- Low beam relay control circuit (QUAD) shorted to ground
- Low beam headlamp relay (QUAD) defective, shorted
- Low beam headlamp relay defective (shorted) by default
- PDC defective (low beam headlamp relay connector shorted)
- Headlamp switch defective - switch sense
- BCM defective (headlamp switch sense function) by default
- BCM defective (low beam relay control shorted) by default
Headlamps Will Not Turn On
SYMPTOM
* HEADLAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch ground circuit open
- Both low beam fuses open
- Fused low beam output circuit open (both lamps inoperative)
- Fused low beam output circuit open (one lamp inoperative)
- Headlamp defective (by default)
- Headlamp fuse open
- Headlamp switch sense circuit open
- Headlamps defective (by default)
- Multifunction switch defective (default)
- Headlamp relay control circuit open
- Low beam relay control circuit (Chrysler) open
- Low beam relay control circuit open
- Low beam headlamp relay defective (by default)
- Low beam relay defective - relay control function
- PDC defective - B(+) circuit at low beam fuse terminal
- Power Distribution Center defective (low beam relay CAV A)
- Power Distribution Center defective (low beam relay CAV B)
- Headlamp switch defective (by default)
- BCM defective - headlamp switch sense function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2693
- BCM defective - headlamp switch sense stuck open
- BCM defective - low beam relay control open
Park Lamps Will Not Turn Off
SYMPTOM
* PARK LAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Park lamp relay control circuit shorted to ground
- Park lamp relay output circuit shorted to voltage
- Park lamp switch sense circuit shorted to ground
- Park lamp relay defective - control shorted (by default)
- Headlamp switch defective - shorted
- BCM defective - park lamp switch sense closed (by default)
Park Lamps Will Not Turn On
SYMPTOM
* PARK LAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch ground circuit open
- Fused park lamp output circuit open
- Park lamp bulb defective (by default)
- Park lamp fuse in PDC open
- Both park lamp fuses open
- Park lamp fuse open
- Park lamp relay control circuit open
- Park lamp relay output circuit open
- Park lamp switch sense circuit open
- Park lamp relay defective (control function)
- PDC defective - other B(+) cavity
- PDC defective - park lamp relay connector, fused B(+)
- Headlamp switch defective - park lamps (by default)
- BCM defective - park lamp switch sense stuck open
- BCM defective - park lamp switch sense function
- BCM defective - parklamp control function (by default)
ABS Warning Lamp
SYMPTOM
* ABS WARNING LAMP
POSSIBLE CAUSES
- BCM connector observable defect
- CAB connector observable defect
- Fused ignition switch output circuit open
- ABS warning lamp defective
- ABS warning lamp driver circuit open
- ABS warning lamp driver circuit shorted to ground
- ABS warning lamp flashing
- BCM defective
- CAB defective
Airbag Warning Lamp
SYMPTOM
* AIRBAG WARNING LAMP
POSSIBLE CAUSES
- Airbag warning lamp failure
All Warning Lamps Out
SYMPTOM
* ALL WARNING LAMPS OUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2694
POSSIBLE CAUSES
- Fused B(+) circuit open
- Fused ignition switch output circuit open
- Ground circuit open
- Information Center defective
Engine Temperature Warning Lamp
SYMPTOM
* ENGINE TEMPERATURE WARNING LAMP
POSSIBLE CAUSES
- Engine temperature lamp staying on
- Temperature lamp not working
- Engine temperature lamp/bulb defective
- Fused ignition switch output circuit open
- Defective BCM
- Engine temperature warning lamp driver circuit open
- Temperature warning lamp driver circuit shorted to ground
- Information Center defective
- Body Control Module defect
- Defective Information Center
High Beam Indicator Lamp
SYMPTOM
* HIGH BEAM INDICATOR LAMP
POSSIBLE CAUSES
- Headlamps inoperative
- Fused right highbeam output circuit open
- Ground circuit open
- High beam indicator bulb defective
- Defective Information Center
Low Oil Pressure Warning Lamp
SYMPTOM
* LOW OIL PRESSURE WARNING LAMP
POSSIBLE CAUSES
- Oil pressure low
- Oil warning lamp/bulb defective
- Oil level low
- Defective oil pressure switch
- Oil pressure switch sense circuit shorted to ground
- Oil pressure switch sense circuit open
- Oil pressure switch defective
- BCM defective
- Defective Information Center
Red Brake Warning Lamp
SYMPTOM
* RED BRAKE WARNING LAMP
POSSIBLE CAUSES
- Park brake pedal problem
- Vehicle equipped antilock brakes
- Brake fluid level low
- Red brake warn lamp/bulb defective
- Ground circuit open
- Brake fluid level switch defective
- Defective ignition switch
- Defective park brake switch
- Red brake warning lamp circuit open
- Red brake warning lamp circuit shorted to ground
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2695
- Information Center faulty
- Ignition switch defective
- Red brake warning lamp driver circuit open
- Red brake warning lamp driver circuit faulty
Service Engine Soon Lamp
SYMPTOM
* SERVICE ENGINE SOON LAMP
POSSIBLE CAUSES
- DTC's are present
- Bulb & socket defective
- Service Engine Soon indicator lamp driver circuit open
- Service Engine Soon indicator lamp circuit shorted to ground
- Defective Information Center circuit board
- Powertrain Control Module defective
Turn Signal Indicator Lamp
SYMPTOM
* TURN SIGNAL INDICATOR LAMP
POSSIBLE CAUSES
- Turn signal lamps inoperative
- Ground circuit open
- Left turn signal circuit open
- Right turn signal circuit open
- Turn signal bulbs defective
- Junction Block defective
- BCM defective
- Information Center defective
Vehicle Theft Alarm Indicator
SYMPTOM
* VEHICLE THEFT ALARM INDICATOR
POSSIBLE CAUSES
- Vehicle theft alarm indicator defective
All Gauges Inoperative
SYMPTOM
* ALL GAUGES NOT OPERATING
POSSIBLE CAUSES
- BCM instrument cluster circuit output defective
- Instrument Cluster PC board defective
- DRB shows ignition unlock closed
- No response - CCD bus instrument cluster
- Body computer odometer failure
- RAM test failure
- ROM test failure
Cluster Illumination
SYMPTOM
* CLUSTER ILLUMINATION
POSSIBLE CAUSES
- No response - CCD bus instrument cluster
- Headlamp switch ground circuit defective
- Inoperative lamp defective
- Headlamp switch defective
- Junction block defective
- Dimmer switch signal circuit open
- Dimmer switch signal circuit shorted to ground
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2696
- Instrument panel lamps driver circuit shorted to ground
- Panel lamps driver circuit open
- Park lamps not lighting
- Instrument Cluster circuit board defective
- BCM dimmer switch signal circuit output faulty
- BCM defective
- BCM defective by default
- Body computer odometer failure
- BCM dimmer switch signal circuit defective
- Illumination panel fuse OK
- Inoperative lamp ground circuit
- RAM test failure
- ROM test failure
Cluster Warning Lamps Odometer and PRNDL Display
SYMPTOM
* CLUSTER WARNING LAMPS ODOMETER AND PRNDL DISPLAY
POSSIBLE CAUSES
- Any one lamp/bulb defective
- Washer fluid level switch sense circuit open
- Washer fluid level switch sense ground circuit open
- Washer fluid level switch sense circuit shorted
- Body computer odometer failure DTC
- No response - CCD bus instrument cluster
- Washer fluid level switch defective
- BCM washer fluid switch sense circuit input defective
- All segments fail to light
- Faulty odometer and PRNDL lamp
- Generator lamp failure
- Instrument cluster printed circuit board defective
Gauges Not Returning to Zero With Key Off
SYMPTOM
* GAUGES NOT GOING TO ZERO WHEN KEY IS TURNED OFF
POSSIBLE CAUSES
- Fused B(+) circuit open
- No response - CCD bus instrument cluster
- Instrument Cluster PC board defective
- Body computer odometer failure
- RAM test failure
- ROM test failure
One Gauge Not Operating Properly
SYMPTOM
* ONE GAUGE OPERATING IMPROPERLY
POSSIBLE CAUSES
- DRB reads active on the bus
- DRB reads no vehicle speed sense signal code
- IOD fuse is loose in junction block
- Speedometer calibration out
- Any one lamp/bulb defective
- DRB reading not matching RPM
- Washer fluid level switch sense circuit open
- Washer fluid level switch sense ground circuit open
- Washer fluid level switch sense circuit shorted
- Washer fluid level switch defective
- Gauge pack defective
- Speedometer/Odometer gauge pack defective
- Tachometer calibration out
- Cooling system condition faulty
- DRB reads coolant temperature sensor code
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2697
- DRB reads engine temperature accurately
- BCM instrument cluster circuit output defective
- Body Control Module defective
- Gauge pack defective
- Instrument Cluster printed circuit board defective
- DRB shows ignition unlock closed
- BCM washer fluid level switch sense circuit input defective
- All segments fail to light
- BCM temperature gauge input defective
- Faulty odometer and PRNDL lamp
- Generator lamp failure
- PCM defective
- Pinion factor failure
Trip and Rest Button(S)
SYMPTOM
* TRIP AND RESET BUTTON(S)
POSSIBLE CAUSES
- Trip & reset button(s) defective
Courtesy Lamps Inoperative W/Dome Lamp Switch
SYMPTOM
* COURTESY LAMPS INOPERATIVE W/DOME LAMP SWITCH
POSSIBLE CAUSES
- Courtesy lamp switch sense circuit open
- Headlamp switch defective - courtesy lamp function open
- BCM defective - courtesy lamp switch sense (by default)
- BCM defective - dome lamp switch function
Courtesy Lamps Inoperative With Any Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH ANY DOOR
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Courtesy lamp relay control circuit open
- Switched courtesy lamp relay control circuit open
- Junction block defective - lamp relay fused B(+) (CAV 87) open
- Courtesy lamp relay defective - coil open
- Junction block defective - lamp relay fused B(+) (CAV 30) open
- Junction block defective - lamp relay fused B(+) (CAV 86) Open
- Headlamp switch defective - open
- BCM defective - lamp relay control function (by default)
- BCM defective - driver door ajar switch status
Courtesy Lamps Inoperative With Driver Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH DRIVER DOOR
POSSIBLE CAUSES
- Driver door ajar switch defective, open
- Driver door ajar switch sense circuit open
- Left front door switch ground strap corroded/damaged
- Body Control Module inoperative, open
Courtesy Lamps Inoperative With Left Sliding Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH LEFT SLIDING DOOR
POSSIBLE CAUSES
- Left sliding door ajar switch sense circuit open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2698
- Left sliding door ajar ground circuit open
- Left sliding door ajar switch defective, open
- BCM defective
Courtesy Lamps Inoperative With Liftgate
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH LIFTGATE
POSSIBLE CAUSES
- Liftgate ground circuit open
- Liftgate ajar switch open - ajar switch disconnected
- Liftgate ajar switch sense circuit open
- BCM defective, open
Courtesy Lamps Inoperative With Passenger Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH PASSENGER DOOR
POSSIBLE CAUSES
- Passenger door ajar switch defective, open
- Passenger door ajar switch sense circuit open
- Right front door switch ground strap corroded/damaged
- Body Control Module inoperative, open
Courtesy Lamps Inoperative With Right Sliding Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH RIGHT SLIDING DOOR
POSSIBLE CAUSES
- Right sliding door ajar switch defective, open
- Right sliding door ajar switch sense circuit open
- Right sliding door ajar ground circuit open
- BCM defective, open
Courtesy Lamps On at All Times
SYMPTOM
* COURTESY LAMPS ON AT ALL TIME
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Courtesy lamp relay output circuit shorted to B(+)
- Courtesy lamp relay control circuit shorted to ground
- Switched courtesy lamp relay control circuit shorted to ground
- Courtesy lamp relay defective - coil shorted
- Headlamp switch shorted
- BCM defective - relay control shorted (by default)
Illuminated Entry Inoperative With Driver Door Key Cylinder
SYMPTOM
* ILLUMINATED ENTRY INOPERATIVE WITH DRIVER DOOR KEY CYLINDER
POSSIBLE CAUSES
- Driver door key switch unlock position stuck
- Driver door key cylinder switch defective
- Driver door key switch sticking
Illuminated Entry Inoperative With RKE Transmitter
SYMPTOM
* ILLUMINATED ENTRY INOPERATIVE WITH RKE TRANSMITTER
POSSIBLE CAUSES
- RKE circuit at BCM defective
- RKE ground circuit open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2699
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- Defective door lock switch
- Defective unlock switch
- RKE module default replacement
- RKE module defective
CMTC Avg MPH/Fuel Economy Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE OR
WRONG
POSSIBLE CAUSES
- No PCM communications
- TPS inoperative
- VSS signal inoperative
CMTC Elapsed Time Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER ELAPSED TIME INOPERATIVE OR WRONG
POSSIBLE CAUSES
- Defective BCM / Indicator lights
CMTC Fails to Respond to Instrument Cluster Dimming
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER
DIMMING
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer
CMTC Trip Odometer Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER TRIP ODOMETER INOPERATIVE OR WRONG
TEST NOTE
This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER AVG MPH OR
FUEL ECONOMY INOPERATIVE/WRONG.
POSSIBLE CAUSES
- No PCM communications
- TPS inoperative
- VSS signal inoperative
Compass/Mini-Trip Computer Displaying OC
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER DISPLAYING OC
POSSIBLE CAUSES
- Open sensor ground circuit
- Ambient Temperature Sensor defective
- Open Ambient Temperature Sensor signal circuit
- Defective Compass/Mini-Trip Module - sensor ground circuit.
Compass/Mini-Trip Computer Displaying SC
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER DISPLAYING SC
POSSIBLE CAUSES
- Defective Ambient Temperature Sensor
- Ambient Temperature Sensor signal circuit shorted to ground
- Compass/Mini-Trip Module default
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2700
Compass/Mini-Trip Computer Segments Fail to Light
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SEGMENTS FAIL TO LIGHT
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer - segments fail to light
Compass/Mini-Trip Computer Shows Failed
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SHOWS FAILED
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer - shows failed
Compass/Mini-Trip Computer Switch Inoperative
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER FAILS TO
RESPOND TO INSTRUMENT CLUSTER DIMMING.
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer
Incorrect Ambient Temperature Readings
SYMPTOM
* INCORRECT AMBIENT TEMPERATURE READINGS
POSSIBLE CAUSES
- Open sensor ground - defective CMTM
- Sensor ground circuit partial short to ground
- Defective Ambient Temperature Sensor/Road test
- Ambient Temperature Sensor signal circuit partial short
- Ambient Temperature Sensor signal circuit shorted
- Defective Compass/Mini-Trip Module
- Defective Compass/Mini-Trip Module sensor ground circuit
Add'l All Doors (Exc Drvr w/RKE) Fail Lck/Unlckfrom Any Switch
SYMPTOM
ADDITIONAL ALL DOORS (EXCEPT DRVR W/RKE) FAIL LCK/UNLCK FROM ANY SWITCH
POSSIBLE CAUSES
- Junction block defective
- Door unlock relay output circuit open
- Door unlock relay output circuit resistance low
Additional All Doors (Exc Driver w/RKE) Fail to Unlock
SYMPTOM
ADDITIONAL ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK
POSSIBLE CAUSES
- Fused B(+) circuit voltage too low at junction block
- Door unlock relay control inoperative at BCM
- Door unlock relay defective
- Door unlock relay coil resistance out of tolerance
- Door unlock relay output circuit shorted to ground
Additional All Doors Fail to Lock and Unlock From Any Switch
SYMPTOM
* ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2701
POSSIBLE CAUSES
- Passenger door switch MUX shorted to battery
- Door lock switch resistance high in unlock position
- Driver door switch MUX circuit shorted to battery
- Liftgate switch MUX shorted to battery
- BCM door lock relay control circuit inoperative
- Liftgate switch MUX at BCM defective
- Door lock relay control ground circuit open
- Door lock relay defective
- Fuse # 26 defective
- Fused B(+) circuit open
- Fused B(+) circuit shorted to ground
- Ground circuit open at door lock relay connector
Additional All Doors Fail to Lock and Unlock From One Switch
SYMPTOM
ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH
POSSIBLE CAUSES
- Door key cylinder switch connector circuit ground circuit open
- Door key cylinder switch defective
- Liftgate key cylinder switch defective
- Liftgate switch MUX shorted to battery
- Door switch MUX circuit to BCM open
- Driver door switch MUX circuit open at BCM connector
- Liftgate switch MUX circuit open at BCM connector
- Liftgate switch MUX circuit to BCM open
- Passenger door switch MUX circuit open at BCM connector
- Passenger door switch MUX circuit to BCM open
- Door lock switch connector ground circuit open
- Door lock switch defective
- Door lock switch MUX circuit open
- Door locks inoperative from key cylinder switch
- Door switch MUX circuit shorted to battery
Additional All Doors Failing to Lock From Any Switch
SYMPTOM
ADDITIONAL ALL DOORS FAILING TO LOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Fused B(+) circuit voltage too low at junction block
- Door lock relay control circuit from BCM fails
- Key - in ignition switch circuit to BCM defective
- Door lock relay does not operate
- Door lock relay coil resistance out of tolerance
- Door lock relay output shorted to ground
- Ignition switch defective
- Key - in ignition switch sense circuit shorted to ground
Additional Driver Door (w/RKE) Failing to Unlock From Any SW
SYMPTOM
ADDITIONAL DRIVER DOOR (W/RKE)FAILING TO UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Driver door unlock relay coil resistance out of tolerance
- Driver door unlock relay defective
- Driver door unlock relay output circuit shorted to ground
- Voltage too low at junction block fused B(+) circuit
Additional One Door Fails to Lock and Unlock From Any Switch
SYMPTOM
ADDITIONAL ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2702
POSSIBLE CAUSES
- RKE equipped door lock fails to lock & unlock
- Door lock motor defective
- Driver unlock relay ground open in junction block
- Door lock relay output circuit open
- Door unlock relay output circuit open
- Driver door unlock relay open
All Doors (Exc Driver w/RKE) Fail Lock/Unlock From Any Switch
SYMPTOM
* ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors (Exc Driver w/RKE) Fail to Unlock
SYMPTOM
* ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK
POSSIBLE CAUSES
- RKE circuit at BCM defective
- RKE ground circuit open
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- Defective door lock switch
- Defective door unlock switch
- RKE module default replacement
- RKE module defective
All Doors Fail to Lock and Unlock From Any Switch
SYMPTOM
* ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Link to body communication bus inoperative
- Defective door lock switch
- Defective unlock switch
All Doors Fail to Lock and Unlock From One Switch
SYMPTOM
* ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors Failing to Lock From Any Switch
SYMPTOM
* ALL DOORS FAILING TO LOCK FROM ANY SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2703
- Defective unlock switch
All Doors Failing to Lock From One Switch
SYMPTOM
* ALL DOORS FAILING TO LOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors Failing to Unlock From One Switch
SYMPTOM
* ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
Automatic Door Locks Do Not Lock Over 15 MPH
SYMPTOM
* AUTOMATIC DOOR LOCKS DO NOT LOCK OVER 15 MPH
POSSIBLE CAUSES
- Link to body communication bus inoperative
- TPS malfunction causes door lock problem
- VSS malfunction causes door lock problem
- Auto door lock not enabled
Doors Lock With Key In Ignition and Left Door Open
SYMPTOM
* DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN
POSSIBLE CAUSES
- Link to body communication bus inoperative
- BCM defective
- BCM sends wrong key - in ignition status
- BCM a connector terminals damaged
- Ignition switch open
- Key - in ignition switch ground circuit open
- Key - in ignition switch sense circuit open
Driver Door (w/RKE) Failing to Unlock From Any Switch
SYMPTOM
* DRIVER DOOR (W/RKE) FAILING TO UNLOCK FROM ANY SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
One Door Fails to Lock and Unlock From Any Switch
SYMPTOM
* ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2704
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
Remote Keyless Entry Problem
SYMPTOM
* RKE PROBLEM
POSSIBLE CAUSES
- Link to body communication bus inoperative
- RKE circuit at BCM defective
- RKE ground circuit open
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- RKE module default replacement
- RKE module defective
Front Wiper Operating Constantly W/Switch In Off Position
SYMPTOM
* FRONT WIPER OPERATING CONSTANTLY W/SWITCH IN OFF POSITION
POSSIBLE CAUSES
- Front wiper ON/OFF relay control circuit shorted to ground
- Defective wiper ON relay/substitute relay
- Defective multifunction switch/voltage
- High/Low wiper relay HI speed output circuit shorted to voltage
- High/Low wiper relay LO speed output circuit shorted to voltage
- Defective BCM - 100 ohms default
Front Wipers Not Parking In Off Position
SYMPTOM
* FRONT WIPERS NOT PARKING IN OFF POSITION
TEST NOTE
This symptom is diagnosed using the test FRONT WIPER PARK SWITCH CIRCUIT OPEN
POSSIBLE CAUSES
- Wiper park switch toggle closed/open
- Open wiper park switch sense circuit
- Defective BCM - wiper park switch
- Defective wiper motor/wiper park switch
Front Wipers Not Working at All
SYMPTOM
* FRONT WIPERS NOT WORKING AT ALL
POSSIBLE CAUSES
- Open wiper on relay control circuit - BCM/wiper relay
- Defective wiper ON relay - BCM/ground
- Front wiper switch MUX circuit shorted to ground
- Open front wiper switch MUX circuit between switch and BCM
- Defective High/Low wiper relay - relay connector
- Defective multifunction switch/front wiper switch
- High/Low wiper relay HI speed output circuit shorted to ground
- High/Low wiper relay LO speed output circuit shorted to ground
- Open ground circuit/lights
- Open High/Low relay LO speed output circuit between High/Low relay and wiper motor
- Open fused ignition switch output circuit/multifunction switch
- Defective Power Distribution Center - relay connector
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2705
- Defective Power Distribution Center - front wiper relay
- Defective Power Distribution Center - wiper ON relay
- Defective Power Distribution Center - wiper relay
- Defective Power Distribution Center - H/L relay
- Defective Power Distribution Center - B(+) circuit.
- Defective wiper motor/harness
- Defective BCM/wiper relay
- Defective BCM/front wiper MUX
- Defective BCM/sensors
- Defective wiper motor ground circuit.
Front Wipers Not Working In High Speed Mode
SYMPTOM FRONT WIPERS NOT WORKING IN HIGH SPEED MODE
POSSIBLE CAUSES
- Open HI/LO wiper relay control circuit
- Defective HI/LO wiper RELAY - Wiper switch
- Open wiper HI/LO relay HI speed output circuit
- Defective multi - FUNCT switch/ ground circuit
- Defective power DIST CNTR-H/L WPR RLY
- Defective wiper Motor/HI speed output circuit
- Open ground circuit/Multi - Function switch
Front Wipers Not Working In Intermittent Mode
SYMPTOM
* FRONT WIPERS NOT WORKING IN INTERMITTENT MODE
POSSIBLE CAUSES
- Defective multifunction switch/positions
- Defective BCM/wiper positions
- Defective multifunction switch/Default
Front Wipers Not Working In Low Speed Mode
SYMPTOM
* FRONT WIPERS NOT WORKING IN LOW SPEED MODE
POSSIBLE CAUSES
- High/Low wiper relay control circuit shorted to ground
- Defective High/Low wiper relay - fused ignition switch
- Open High/Low wiper relay - LO speed output circuit
- Defective wiper motor/LO speed output circuit
Rear Washer Motor Inoperative
SYMPTOM
* REAR WASHER MOTOR INOPERATIVE
POSSIBLE CAUSES
- Open rear washer motor control circuit
- Defective rear washer motor/jumper
- Open fused ignition switch output circuit/voltage
- Defective HVAC Control Module / 3.8 volts
- Defective BCM - washer motor operate
Rear Wiper Not Parking In the Off Position
SYMPTOM
* REAR WIPER NOT PARKING IN THE OFF POSITION
POSSIBLE CAUSES
- Rear wiper motor control circuit shorted to battery
- Defective HVAC Control Module/switch indicator lights
- Defective wiper motor/wiper motor connector
- Defective BCM/rear wiper motor - default
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Related Diagnostic Procedures > Page 2706
- Defective BCM/washer motor run
- Defective BCM/cycle on default
- Defective BCM/rear wiper switch voltage
- Defective rear wiper motor/test light
Rear Wiper Not Working at All
SYMPTOM
* REAR WIPER NOT WORKING AT ALL
POSSIBLE CAUSES
- Open rear wiper motor control circuit
- Open rear wiper switch MUX circuit
- Open ground circuit/rear wiper motor
- Open fused ignition switch output circuit/fuse # 6
- Open fused ignition switch output circuit/fuse # 8
- Shorted fused ignition switch output circuit/fuse # 6
- Defective rear wiper motor/motor control
- Defective HVAC Control Module/default
- Defective HVAC Control Module/rear wiper switch MUX
- Defective BCM/rear wiper switch MUX
- Defective BCM/rear wiper motor
- Defective HVAC Control Module/21-Way connector
Rear Wiper Not Working In the Intermittent Mode
SYMPTOM
* REAR WIPER NOT WORKING IN THE INTERMITTENT MODE
POSSIBLE CAUSES
- Defective rear wiper motor/intermittent switch
- Defective HVAC Control Module/indicator light
- Defective HVAC Control Module/rear wiper switch
- Defective BCM/test light default
Rear Wiper/Wash Working Continuously
SYMPTOM
* REAR WIPER/WASH WORKING CONTINUOUSLY
POSSIBLE CAUSES
- Rear wiper motor control circuit shorted to battery
- Defective wiper motor/wiper motor connector
- Defective BCM/rear wiper motor - default
- Defective BCM/washer motor run
- Defective BCM/rear wiper switch voltage
Wiper/Wash Function Not Working Properly
SYMPTOM
* WIPER/WASH FUNCTION NOT WORKING PROPERLY
POSSIBLE CAUSES
- Defective washer motor/washer pump control
- Operate wipers
- Open washer pump control circuit
- Defective multifunction switch/washer pump control
- Open fused ignition switch output circuit
- Defective junction block/BCM
- Defective junction block/block connector
- Defective BCM/junction block
- Defective BCM/stalk switch
- Fused ignition switch output circuit shorted to ground
- Open washer pump control circuit/multifunction switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom
Related Diagnostic Procedures > Page 2707
Body Control Module: Component Tests and General Diagnostics
Six-Step Troubleshooting Procedure
Diagnosis of the body system is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
Road Testing A Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE
REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN
WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE
IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB.
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Related Diagnostic Procedures > Page 2708
Body Control Module: Scan Tool Testing and Procedures
Under normal operation, the DRB will display one of only two error messages: - User-Requested
WARM Boot or User-Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the MDS
Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error
message display:
ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD
Boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRB III (R) Does Not Power up (Blank Screen) If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data
link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A.
DRB Scan Tool
Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to
compensate for this condition
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2709
Body Control Module: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove lower steering column cover and
knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control
Module (BCM)
Body Control Module - Location
4. Remove bolts holding Junction Block to dash panel mounting bracket. 5. Remove Junction Block
from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide
Body Control Module downward to disengage guide studs on Junction Block from channels on
BCM mounting bracket. 8. Remove Body Control Module from Junction Block.
INSTALLATION
For installation, reverse the above procedures.
REMOVAL AND INSTALLATION
Refer to Instrument Panel and Systems, Body Control Module Replacement.
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Body Control Module: Tools and Equipment
DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires
ohmmeter voltmeter oil pressure gauge (0-300 psi) test light
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Locations
Powertrain Control Module: Locations
Power Distribution Center & Powertrain Control Module (PCM)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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Diagrams > Diagram Information and Instructions > Page 2716
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Diagrams > Diagram Information and Instructions > Page 2717
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Diagrams > Diagram Information and Instructions > Page 2718
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Diagrams > Diagram Information and Instructions > Page 2719
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Diagrams > Diagram Information and Instructions > Page 2720
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Diagrams > Diagram Information and Instructions > Page 2722
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Diagrams > Diagram Information and Instructions > Page 2723
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Diagrams > Diagram Information and Instructions > Page 2724
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diagrams > Diagram Information and Instructions > Page 2725
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Powertrain Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Powertrain Control Module: Connector Views
Powertrain Control Module C1
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Powertrain Control Module C2
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Powertrain Control Module: Description and Operation
OPERATION
Powertrain Control Module
The ignition system is regulated by the Powertrain Control Module (PCM). The PCM supplies
battery voltage to the ignition coil through the Auto Shutdown (ASD) Relay. The PCM also controls
ground circuit for the ignition coil. By switching the ground path for the coil on and off, the PCM
adjusts ignition timing to meet changing engine operating conditions.
During the crank-start period the PCM advances ignition timing a set amount. During engine
operation, the amount of spark advance provided by the PCM is determined by the following input
factors: available manifold vacuum
- barometric pressure
- engine coolant temperature
- engine RPM
- throttle position
The PCM also regulates the fuel injection system. Refer to the Fuel Injection.
The speed control electronic control circuitry is integrated into the Powertrain Control Module
(PCM). The PCM is located in the engine compartment. The PCM speed control functions are
monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the
PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a
DTC in electronic memory for any failure it detects. The PCM cannot be repaired and must be
replaced if faulty.
USE THE DRB SCAN TOOL TO REPROGRAM THE NEW PCM WITH THE VEHICLES
ORIGINAL IDENTIFICATION NUMBER (OIN) AND THE VEHICLES ORIGINAL MILEAGE. IF
THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
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Powertrain Control Module: Service and Repair
REMOVAL
1. Disconnect both cables from battery, negative cable first.
NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after
disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection
Power Distribution Center Retaining Screws
2. Remove 2 screws holding Power Distribution Center (PDC) to bracket.
Battery Heat Shield
3. Remove heat shield from battery.
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Battery Clamp
4. Remove nut and clamp holding battery to battery tray. 5. Remove battery from vehicle.
PDC Rear Bracket
6. Rotate PDC toward center of vehicle to remove from rear bracket. 7. Pull PDC rearward to
remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM).
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PCM 40-way Connectors
8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM. Remove both
way connectors.
PCM Removal/Installation
9. Remove 3 screws holding PCM to fender.
10. Remove PCM from vehicle.
INSTALLATION
1. Connect 2 40-Way electrical connectors to PCM. 2. Install PCM. Tighten mounting screws. 3.
Install PDC bracket. 4. Install battery.
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Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Battery Negative Cable
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Component Information > Locations > Page 2743
Power Distribution Center -- Sheet 8w-10-2
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Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 2758
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Component Information > Diagrams > Diagram Information and Instructions > Page 2759
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2760
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Component Information > Diagrams > Diagram Information and Instructions > Page 2761
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Component Information > Diagrams > Diagram Information and Instructions > Page 2762
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 2763
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2764
Automatic Shut Down (ASD) Relay: Connector Views
Power Distribution Center
Automatic Shut Down Relay
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Component Information > Diagrams > Page 2765
Automatic Shut Down (ASD) Relay: Description and Operation
Power Distribution Center
DESCRIPTION
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and
fuses in the PDC.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02
Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM
monitors the crankshaft position sensor and camshaft position sensor signals to determine engine
speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor
and camshaft position sensor signals when the ignition switch is in the Run position, it will
de-energize the ASD relay.
AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT
OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt
signal at this input indicates to the PCM that the ASD has been activated. This input is used only to
sense that the ASD relay is energized.
When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC).
AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT
The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic
ignition coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and
contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss
bar in the PDC and the relay. The fuse is located in the PDC.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2
Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the
On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position
sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not
receive the crankshaft position sensor and camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the ASD relay.
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Component Information > Diagrams > Page 2766
Power Distribution Center
The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies
the relays and fuses in the PDC.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
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Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2769
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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Component Information > Testing and Inspection > Page 2770
Automatic Shut Down (ASD) Relay: Service and Repair
The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover
has a label showing relay and fuse location.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation
Battery Temperature Sensor: Description and Operation
OPERATION
The temperature sensor, in the PCM, is used to determine the battery temperature. This
temperature data, along with data from monitored line voltage, is used by the PCM to vary the
battery charging rate. System voltage will be higher at colder temperatures and is gradually
reduced at warmer temperatures.
The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II
monitors are either enabled or disabled depending upon the battery temperature sensor input
(example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor ...................................................................................................................
................................................... 14 Nm (125 in. lbs.)
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Camshaft Position Sensor: Description and Operation
Camshaft Position Sensor Location
DESCRIPTION
The camshaft position sensor is mounted in the front of the timing case cover.
Camshaft Position Sensor
Camshaft Sprocket
OPERATION
The camshaft position sensor provides cylinder identification to the Powertrain Control Module
(PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass
underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the
pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each
group of camshaft pulses.
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When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Ignition Coil Pack
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder
the flat spot and notches identify, they do not indicate TDC position.
CAMSHAFT POSITION SENSOR-PCM INPUT
The PCM determines fuel injection synchronization and cylinder identification from inputs provided
by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM
determines crankshaft position.
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it.
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft
pulses.
The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of
the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel
Injection-Service Procedures.
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Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
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Camshaft Position Sensor: Service and Repair
REMOVAL
Camshaft Position Sensor
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector.
Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt.
Camshaft Sensor Removal/Installation
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3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the
sensor lead. There is an O-ring on the sensor case. The O-ring may make removal
difficult. A light tap to top of sensor prior to removal may reduce force needed for removal.
INSTALLATION
Camshaft Position Sensor And Spacer
If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If
the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is
positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring
prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor
down until contact is made with the camshaft gear. While holding the sensor in this position, install
and tighten the retaining bolt 14
Nm (125 in. lbs.) torque.
4. Connect camshaft position sensor electrical connector to harness connector.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Temperature Sensor 7 Nm
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Specifications > Page 2788
Coolant Temperature Sensor/Switch (For Computer): Locations
Engine Coolant Temperature Sensor
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Specifications > Page 2789
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Specifications > Page 2790
Coolant Temperature Sensor/Switch (For Computer): Service Precautions
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE ENGINE COOLANT
TEMPERATURE (ECT) SENSOR.
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Specifications > Page 2791
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
ENGINE COOLANT TEMPERATURE SENSOR-PCM INPUT
The engine coolant temperature sensor is a variable resistor with a range of -40° C to 129° C (-40°
F to 265° F).
The engine coolant temperature sensor provides an input voltage to the PCM. As coolant
temperature varies, the sensor resistance changes resulting in a different input voltage to the PCM.
When the engine is cold, the PCM will demand slightly richer air/fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The engine coolant sensor is also used for cooling fan control.
Engine Coolant Temperature Sensor
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
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Specifications > Page 2792
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Engine Coolant Temperature Sensor
1. With the key off, disconnect wire harness connector from coolant temperature sensor.
Engine Coolant Temperature Sensor
2. Connect a high input impedance (digital) voltohmmeter to terminals A and B. The ohmmeter
should read as follows:
a. ECT STET at normal operating temperature around 200°F should read approximately 700 to
1,000 ohms. b. ECT STET at room temperature around 70°F ohmmeter should read approximately
7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater
than 1 ohm, repair the wire harness as necessary.
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Specifications > Page 2793
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Engine Coolant Temperature Sensor
The sensor is installed next to the thermostat housing.
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING
SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT
TEMPERATURE SENSOR.
REMOVAL
1. With the engine cold, drain coolant until level drops below cylinder head. 2. Disconnect coolant
sensor electrical connector. 3. Remove coolant sensor.
INSTALLATION
1. Install coolant sensor. Tighten sensor to 7 Nm (60 in. lbs.) torque. 2. Attach electrical connector
to sensor. 3. Fill cooling system.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
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Crankshaft Position Sensor Location
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Crankshaft Position Sensor: Description and Operation
DESCRIPTION
Crankshaft Position Sensor Location
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing. The bottom of the sensor is positioned next to the drive plate.
OPERATION
Crankshaft Position Sensor
Timing Slots
The crankshaft position sensor detects slots cut into the transmission driveplate extension. There
are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the
position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last
slot,
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2800
it determines crankshaft position (which piston will next be at TDC) from the camshaft position
sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°,
and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
CRANKSHAFT POSITION SENSOR-PCM INPUT
The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3
sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of
the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position
(which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM
one engine revolution to determine crankshaft position.
The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing
and presence of misfire. Once crankshaft position has been determined, the PCM begins
energizing the injectors in sequence.
The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor.
The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of
sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft
position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2801
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2802
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Raise and support vehicle.
Crankshaft Position Sensor Connector
2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3.
Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out
of the trans axle housing.
INSTALLATION
Crankshaft Position Sensor And Spacer
NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the face of the new sensor.
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
Fuel Level Sensor: Locations
The level sensor is attached to the side of the fuel pump module.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Fuel Level Sensor: Description and Operation
DESCRIPTION
The level sensor is attached to the side of the fuel pump module. The level sensor consists of a
float, an arm, and a variable resistor.
OPERATION
As the fuel level increases, the float and arm move up. This decreases the sending unit resistance,
causing the fuel gauge on the instrument panel to read full.
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Fuel Level Sensor: Testing and Inspection
This procedure tests the resistance of the level sensor itself. It does not test the level sensor circuit.
Level Sensor Diagnosis
The level sensor is a variable resistor. Its resistance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the fuel level changes. To test the level sensor,
connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump
module connector. Move the float lever to the positions shown in the resistance chart. Record the
resistance at each point. Replace the level sensor if the resistance is not within specifications.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2808
Fuel Level Sensor: Service and Repair
REMOVAL
Remove fuel pump module. Refer to Fuel Pump Module.
Fuel Pump/Level Sensor Electrical Connector
1. Depress retaining tab and remove the fuel pump/level sensor connector from the BOTTOM of
the fuel pump module electrical connector.
NOTE: The pump module harness on TOP of flange is not serviceable or removable.
Wire Terminal Locking Wedge
2. Pull off blue locking wedge.
Wire Terminal Locking Finger
3. Using a small screwdriver lift locking finger away from terminal and push terminal out of
connector.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2809
Removing Wires From Connector
4. Push level sensor signal and ground terminals out of the connector.
Loosening Level Sensor
5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing.
Push level sensor down slightly.
Level Sensor Removal/Installation
6. Slide level sensor wires through opening fuel pump module. 7. Slide level sensor out of
installation channel in module.
INSTALLATION
1. Insert level sensor wires into bottom of opening in module.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Groove In Back Side Of Level Sensor
2. Wrap wires into groove in back of level sensor.
Installation Channel
3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into
place. Ensure tab at bottom of sensor locks in place. 4. Install level sensor wires in connector.
Push the wires up through the connector and then pull them down until they lock in place. Ensure
signal and
ground wires are installed in the correct position.
5. Install locking wedge on connector. 6. Push connector up into bottom of fuel pump module
electrical connector. 7. Install fuel pump module. Refer to Fuel Pump Module.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2814
Knock Sensor
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2815
Knock Sensor: Description and Operation
Knock Sensor
KNOCK SENSOR-PCM INPUT
The knock sensor is only on these engines.
The knock sensor threads into the side of the cylinder block in front of the starter. When the knock
sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response,
the PCM retards ignition timing for all cylinders by a scheduled amount.
Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM.
As the intensity of the engine knock vibration increases, the knock sensor output voltage also
increases.
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Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: ignition timing,
cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude
increases with the increase of engine knock. The knock sensor can be tested with a digital
voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to
approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set.
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Knock Sensor: Service and Repair
Knock Sensor
The knock sensor threads into the side of the cylinder block in front of the starter.
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening
effects knock sensor performance, possibly
causing improper spark control.
2. Attach electrical connector to knock sensor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
Sensor Tightening Torque 35 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page
2821
MAP Sensor
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2822
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page
2823
Manifold Pressure/Vacuum Sensor: Description and Operation
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR-PCM INPUT
The PCM supplies 5 volts to the MAP sensor. The MAP sensor converts intake manifold pressure
into voltage. The PCM monitors the MAP sensor output voltage. As vacuum increases, MAP
sensor voltage decreases proportionately. Also, as vacuum decreases, MAP sensor voltage
increases proportionately.
During cranking, before the engine starts running, the PCM determines atmospheric air pressure
from the MAP sensor voltage. While the engine operates, the PCM determines intake manifold
pressure from the MAP sensor voltage.
Based on MAP sensor voltage and inputs from other sensors, the PCM adjusts spark advance and
the air/fuel mixture.
MAP Sensor
MAP Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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2824
MAP Sensor
The MAP sensor mounts to the intake manifold near the throttle body inlet to the manifold. The
sensor connects electrically to the PCM.
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2825
Manifold Pressure/Vacuum Sensor: Testing and Inspection
To perform a complete test of the MAP sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the MAP sensor only, refer to the following:
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
MAP Sensor Connector
1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3.
With the ignition switch ON and the engine not
running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot,
neutral idle speed condition. If OK, go to next step. If not OK, go to step 3.
2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness
condition. Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1
and PCM terminal 43. If OK, go to next step. If not OK, repair as required. 4. Test MAP sensor
supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should
be approximately 5 volts (±
0.5V). Five volts ± 0.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. If
not OK, repair or replace the wire harness as required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page
2826
Manifold Pressure/Vacuum Sensor: Service and Repair
Map Absolute Pressure Sensor
REMOVAL
1. Disconnect electrical connector from MAP sensor. 2. Remove two screws holding sensor to the
intake manifold.
INSTALLATION
1. Reverse the above procedure for installation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications
Oxygen Sensor: Specifications
Upstream and Downstream Oxygen Sensor 27 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations
Oxygen Sensor: Locations Oxygen Sensor Bank Locations
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Oxygen Sensor Bank Locations
> Page 2832
Oxygen Sensor: Locations Oxygen Sensor(s)
Heated Oxygen Sensor
Downstream Heated Oxygen Sensor
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Oxygen Sensor: Diagrams
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Oxygen Sensor: Service Precautions
WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN
SERVICING THE OXYGEN SENSOR
.
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Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (O2S SENSOR)-PCM INPUT
The O2S produce voltages from 0 to 1 volt, depending upon the oxygen content of the exhaust gas
in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air/fuel
mixture), the sensors produces a low voltage. When there is a lesser amount present (rich air/fuel
mixture) it produces a higher voltage. By monitoring the oxygen content and converting it to
electrical voltage, the sensors act as a rich-lean switch.
The oxygen sensors are equipped with a heating element that keeps the sensors at proper
operating temperature during all operating modes. Maintaining correct sensor temperature at all
times allows the system to enter into closed loop operation sooner. Also, it allows the system to
remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM
monitors the O2S input (along with other inputs) and adjusts the injector pulse width accordingly.
During Open Loop operation the PCM ignores the 02 sensor input. The PCM adjusts injector pulse
width based on preprogrammed (fixed) values and inputs from other sensors.
The Automatic Shutdown (ASD) relay supplies battery voltage to both the upstream and
downstream heated oxygen sensors. The oxygen sensors are equipped with a heating element.
The heating elements reduce the time required for the sensors to reach operating temperature.
UPSTREAM HEATED OXYGEN SENSOR
Heated Oxygen Sensor
Heated Oxygen Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Heated Oxygen Sensor
The upstream O2S is located in the exhaust manifold and provides an input voltage to the PCM.
The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to
fine tune the air/fuel ratio by adjusting injector pulse width.
DOWNSTREAM HEATED OXYGEN SENSOR
Downstream Heated Oxygen Sensor
The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic
convertor. The downstream heated oxygen sensor input is used to detect catalytic convertor
deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match
the upstream sensor input except for a slight time delay. By comparing the downstream heated
oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor
efficiency.
When the catalytic converter efficiency drops below emission standards, the PCM stores a
diagnostic trouble code and illuminates the Malfunction Indicator Lamp (MIL). For more information,
refer to Emission Control Systems.
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Oxygen Sensor: Testing and Inspection
Use an ohmmeter to test the heating element of the oxygen sensors. Disconnect the electrical
connector from each oxygen sensor. The white wires in the sensor connector are the power and
ground circuits for the heater. Connect the ohmmeter test leads to terminals of the white wires in
the heated oxygen sensor connector. Replace the heated oxygen sensor if the resistance is not
between 4 and 7 ohms.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen
Sensor Replacement
Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement
REMOVAL
1. Raise and support vehicle.
WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN
SERVICING THE OXYGEN SENSOR.
Oxygen Sensor Grommet Cover
2. Remove grommet cover to expose connector.
Oxygen Sensor Connector Locking Tab
3. Push locking tab back and unplug oxygen sensor electrical connector.
Oxygen Sensor Removal/Installation
4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 5. When the sensor is
removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using
original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen
Sensor Replacement > Page 2841
INSTALLATION
1. Reverse removal procedure to install a new sensor.
New sensors are packaged with compound on the threads and no additional compound is required.
The sensor must be tightened to 27 Nm (20 ft. lbs.) torque.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen
Sensor Replacement > Page 2842
Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement
Upstream Heated Oxygen Sensor
The oxygen sensor is installed in the exhaust manifold .
CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector.
WARNING: THE EXHAUST MANIFOLD AND CATALYTIC CONVERTER MAY BE EXTREMELY
HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR.
REMOVAL
1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such
as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust
manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
New sensors are packaged with compound on the threads and no additional compound is required.
The sensor must be tightened to 27 Nm (20 ft. lbs.) torque.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications
Throttle Position Sensor: Specifications
Throttle Position Sensor Screw 2 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2846
Throttle Position Sensor
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Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2848
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
THROTTLE POSITION SENSOR (TPS)-PCM INPUT
The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a
variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade
position. As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from
approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with
inputs from other sensors, the PCM uses the TPS input to determine current engine operating
conditions and adjust fuel injector pulse width and ignition timing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2849
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to
the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The
center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply
and the remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS
output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output
voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase
as the throttle plate moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM connections before replacing the TPS.
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Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws.
Servicing Throttle Position Sensor
4. Lift throttle position sensor off throttle shaft.
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
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Bulletins > Transmission Range Sensor - Production Change > Page 2855
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
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Bulletins > Transmission Range Sensor - Production Change > Page 2856
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
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Bulletins > Page 2857
Transmission Range Sensor
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Connector Pin Identification
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Transmission Position Switch/Sensor: Description and Operation
Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical
TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT
The park/neutral switch is located on the transaxle housing.
If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral.
This input is used to determine idle speed (varying with gear selection) and ignition timing advance.
The park neutral switch is sometimes referred to as the neutral safety switch.
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Bulletins > Page 2860
Transmission Position Switch/Sensor: Service and Repair
The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
Fig. 20
3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission
range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8.
Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
Fig. 21
11. Place valve body on workbench (Fig. 21).
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Fig. 22
12. Remove TRS retaining screw (Fig. 22).
Fig. 23
13. Remove manual shaft seal (Fig. 23).
Fig. 24
14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24).
INSTALLATION
1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.)
Reseal transaxle oil pan using RTV.
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Vehicle Speed Sensor: Locations
Fig. 26
Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the
PCM. The output speed sensor is located on the side of
the transaxle.
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Vehicle Speed Sensor: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Vehicle Speed Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2885
Vehicle Speed Sensor: Description and Operation
Description
The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC
signals as rotation occurs. They are threaded into the transaxle case and are considered primary
inputs to the Trans- mission Control Module (TCM).
OPERATION
The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of
the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The
TCM interprets this information as input shaft rpm.
The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by
rotation of the rear planetary carrier park pawl lugs. The TCM interprets this information as output
shaft rpm.
The TCM compares the input and output speed signals to determine the following:
^ Transmission gear ratio
^ Speed ratio error detection
^ CVI calculation
The TCM also compares the input speed signal and the engine speed signal to determine the
following:
^ Torque converter clutch slippage
^ Torque converter element speed ratio
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Specifications
Throttle Position Sensor: Specifications
Throttle Position Sensor Screw 2 Nm
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Component Information > Specifications > Page 2889
Throttle Position Sensor
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Component Information > Specifications > Page 2890
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Component Information > Specifications > Page 2891
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
THROTTLE POSITION SENSOR (TPS)-PCM INPUT
The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a
variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade
position. As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from
approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with
inputs from other sensors, the PCM uses the TPS input to determine current engine operating
conditions and adjust fuel injector pulse width and ignition timing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Specifications > Page 2892
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to
the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The
center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply
and the remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS
output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output
voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase
as the throttle plate moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Component Information > Specifications > Page 2893
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws.
Servicing Throttle Position Sensor
4. Lift throttle position sensor off throttle shaft.
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production
Change
Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
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Change > Page 2898
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production
Change > Page 2899
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2900
Transmission Range Sensor
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Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2901
Connector Pin Identification
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2902
Transmission Position Switch/Sensor: Description and Operation
Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical
TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT
The park/neutral switch is located on the transaxle housing.
If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral.
This input is used to determine idle speed (varying with gear selection) and ignition timing advance.
The park neutral switch is sometimes referred to as the neutral safety switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2903
Transmission Position Switch/Sensor: Service and Repair
The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
Fig. 20
3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission
range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8.
Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
Fig. 21
11. Place valve body on workbench (Fig. 21).
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 2904
Fig. 22
12. Remove TRS retaining screw (Fig. 22).
Fig. 23
13. Remove manual shaft seal (Fig. 23).
Fig. 24
14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24).
INSTALLATION
1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.)
Reseal transaxle oil pan using RTV.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations
Vehicle Speed Sensor: Locations
Fig. 26
Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the
PCM. The output speed sensor is located on the side of
the transaxle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Component Information > Diagrams > Diagram Information and Instructions > Page 2911
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Component Information > Diagrams > Diagram Information and Instructions > Page 2912
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Component Information > Diagrams > Diagram Information and Instructions > Page 2913
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Component Information > Diagrams > Diagram Information and Instructions > Page 2914
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2915
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2916
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2917
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2918
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Component Information > Diagrams > Diagram Information and Instructions > Page 2921
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2922
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2923
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2924
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2925
Vehicle Speed Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2926
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2927
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Page 2928
Vehicle Speed Sensor: Description and Operation
Description
The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC
signals as rotation occurs. They are threaded into the transaxle case and are considered primary
inputs to the Trans- mission Control Module (TCM).
OPERATION
The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of
the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The
TCM interprets this information as input shaft rpm.
The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by
rotation of the rear planetary carrier park pawl lugs. The TCM interprets this information as output
shaft rpm.
The TCM compares the input and output speed signals to determine the following:
^ Transmission gear ratio
^ Speed ratio error detection
^ CVI calculation
The TCM also compares the input speed signal and the engine speed signal to determine the
following:
^ Torque converter clutch slippage
^ Torque converter element speed ratio
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component
Information > Description and Operation
Voltage Signal: Description and Operation
BATTERY VOLTAGE-PCM INPUT
The PCM monitors the battery voltage input to determine fuel injector pulse width and generator
field control.
If battery voltage is low the PCM will increase injector pulse width (period of time that the injector is
energized).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation
Catalytic Converter: Description and Operation
There is no regularly scheduled maintenance on any Chrysler catalytic converter. If damaged, the
converter must be replaced.
CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies,
extreme care should be taken with replacement parts. There are internal converter differences
required in some parts of the country.
The combustion reaction caused by the catalyst releases additional heat in the exhaust system.
Causing temperature increases in the area of the reactor under severe operating conditions. Such
conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do
not remove spark plug wires from plugs or by any other means short out cylinders of the exhaust
system if equipped with a catalytic converter. Failure of the catalytic converter can occur due to
temperature increases caused by unburned fuel igniting when passing through the converter.
The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be
used to avoid poisoning the catalyst core. Do not allow engine to operate at fast idle for extended
periods (over 5 minutes). This condition may result in excessive exhaust system and floor pan
temperatures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 2936
Catalytic Converter: Service and Repair
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY
HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE
EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN
WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.
REMOVAL
1. Remove muffler and tailpipe assembly.
Downstream Oxygen Sensor
2. Disconnect downstream oxygen sensor from the catalytic converter pipe. 3. Remove catalytic
converter to exhaust manifold attaching fasteners. 4. Remove catalytic converter and gasket.
INSTALLATION
1. Position new gasket onto manifold flange and install catalytic converter. Tighten fasteners to 28
Nm (250 inch lbs.). 2. Connect downstream oxygen sensor. 3. Install muffler and tailpipe assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 2941
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 2942
Canister Purge Solenoid: Description and Operation
Proportion Purge Solenoid
OPERATION
All vehicles use a proportional purge solenoid. The solenoid regulates the rate of vapor flow from
the EVAP canister to the throttle body. The PCM operates the solenoid.
During the cold start warm-up period and the hot start time delay, the PCM does not energize the
solenoid. When de-energized, no vapors are purged.
The proportional purge solenoid operates at a frequency of 200 hz and is controlled by an engine
controller circuit that senses the current being applied to the proportional purge solenoid and then
adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the
purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold.
DUTY CYCLE EVAP CANISTER PURGE SOLENOID-PCM OUTPUT
The duty cycle EVAP purge solenoid regulates the rate of vapor flow from the EVAP canister to the
throttle body. The PCM operates the solenoid.
During the cold start warm-up period and the hot start time delay, the PCM does not energize the
solenoid. When de-energized, no vapors are purged. The PCM de-energizes the solenoid during
open loop operation.
The engine enters closed loop operation after it reaches a specified temperature and the time delay
ends. During closed loop operation, the PCM energizes and de-energizes the solenoid 5 or 10
times per second, depending upon operating conditions. The PCM varies the vapor flow rate by
changing solenoid pulse width. Pulse width is the amount of time the solenoid energizes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 2943
Duty Cycle EVAP Purge Solenoid
A rubber boot covers the duty cycle EVAP purge solenoid. The solenoid attaches to a bracket
mounted to the right engine mount. The top of the solenoid has the word TOP on it. The solenoid
will not operate properly unless it is installed correctly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 2944
Canister Purge Solenoid: Service and Repair
REMOVAL
Proportional Purge Solenoid Valve
1. Remove vacuum hose and electrical connector from solenoid. 2. Pull solenoid up to remove it
from mounting bracket.
INSTALLATION
Reverse above procedure for installation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations
Evaporative Emission Control Canister: Locations
Evaporative Canister
The canister is attached to the frame under the driver's seat.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations > Page 2948
Evaporative Emission Control Canister: Description and Operation
DESCRIPTION
Evaporative Canister
The canister is attached to the frame under the driver's seat.
OPERATION
All vehicles use a sealed, maintenance free, evaporative (charcoal) canister.
Fuel tank vapor vents into the canister. The canister temporarily holds the fuel vapors until intake
manifold vacuum draws them into the combustion chamber. The canister proportional purge
solenoid allows the canister to be purged at predetermined intervals and engine conditions.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > EVAP System - Leak
Detection Pump Misdiagnosis
Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump
Misdiagnosis
NUMBER: 18-01-00
GROUP: Vehicle Performance
DATE: Feb. 4, 2000
SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR
P0456
MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck
1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA)
Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH)
Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ)
Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ)
GrandCherokee
DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been
replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as
currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494
(LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply
vacuum lines examined for pinches or kinks prior to any LDP component replacement.
The supply vacuum lines should be checked from the engine compartment all the way to the fuel
tank, including the LDP and purge system.
NOTE:
VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR
DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2953
Leak Detection Pump: Specifications
LDP Bolts 9.5 - 14 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2954
Leak Detection Pump: Locations
Leak Detection Pump
The Leak Detection Pump (LDP) is located under the driver's side in the cast cradle under the
steering gear.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2955
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2956
Leak Detection Pump: Description and Operation
Leak Detection Pump (LDP) Operation And Diagnosis
This bulletin describes the theory of operation for the leak detection system. In addition, information
is provided for each of the Diagnostic Trouble Codes (DTC's) as follows:
P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED
P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND
P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT
INTRODUCTION
The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel
system. Leaks in the system, even small ones, can allow fuel vapors to escape into the
atmosphere. Government regulations require on-board testing to make sure that the evaporative
(EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and
blockage. It also performs self-diagnostics.
During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection
Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the
LDP to seal the vent valve and pump air into the system to pressurize
it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The
PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to
maintain pressure in the system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2957
EVAP LEAK DETECTION SYSTEM COMPONENTS
Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to
test for leaks in the system.
EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel
vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of
pressure.
EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge
Orifice: Limits purge volume.
EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while
allowing a vent to atmosphere for the EVAP system.
Leak Detection Pump (LDP) Components
The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP
system vent to atmospheric pressure so the system can be pressurized for leak testing. The
diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure
of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the
LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air
into the EVAP system. This allows detection of leaks and blockage.
The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it
connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve
closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section
of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and
inlet check valve, and pump it out through an outlet check valve into the EVAP system.
The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP
solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to
the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage)
signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to
the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and
off.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2958
LDP AT REST (NOT POWERED)
When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the
internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the
engine vacuum port and opens the atmospheric pressure port connected through the EVAP system
air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric
pressure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2959
DIAPHRAGM UPWARD MOVEMENT
When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading
through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity
above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds
spring force. This upward movement closes the vent valve. It also causes low pressure below the
diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the
diaphragm completes its upward movement, the LDP reed switch turns from closed to open.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2960
DIAPHRAGM DOWNWARD MOVEMENT based on reed switch input, the PCM de-energizes the
LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects
the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push
the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and
opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns
from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity.
During the pumping mode, the diaphragm will not move down far enough to open the vent valve
The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system
begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring
pressure, slowing the pumping action. The PCM watches the time from when the solenoid is
de-energized, until the diaphragm drops down far enough for the reed switch to change from
opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it
takes the reed switch to change state, the tighter the evaporative system is sealed. If the system
pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated.
PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor
diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes
from open to closed, indicating that the diaphragm has moved down. At other times during the test,
the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During
rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of
rapid cycling, the PCM will use a fixed time interval to cycle the solenoid.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2961
Leak Detection Pump: Testing and Inspection
ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST
NOTE: The following values are approximate and vehicle specific. Use the values seen in pre
test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail
1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on
passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40°
F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2.
Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage
between 10 and 15 volts.
NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the
EVAP leak detection test will not run.
4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and
85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute
pressure, not vacuum). 6. No engine stall during test.
If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set:
- P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED
- P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED
- P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED
- P1486 - EVAP LEAK MON PINCHED HOSE FOUND
- P1494 - LEAK DETECTION PUMP SW OR MECH FAULT
- P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT
A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following:
- Purge Solenoid Electrical Fault
- All Engine Controller Self Test Faults
- All Cam And/or Crank Sensor Fault
- All Map Sensor Faults
- Ambient/battery Temperature Sensor Electrical Faults
- All Coolant Sensor Faults
- All TPS Faults
- LDP Pressure Switch Fault
- EGR Solenoid Fault
- All Injector Faults
- Baro Our Of Range
- Vehicle Speed Faults
- LDP Solenoid Circuit
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2962
Figure 6
EVAP leak detection test sequence
When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the
LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm
may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and
a P1494 fault could be set because the PCM is expecting the reed switch to be closed.
After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical
faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP
Leak Detection Test is canceled.
NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a
specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486,
P0442, P0455 and P0441. These temperature calibrations may be different between models.
FIGURE 6 SECTION 2
If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed
when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and
monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed
switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in
memory, and waits until the next time the Enabling Conditions are met to run the test again. If this
is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during
the next enabling cycle, the temporary fault will be cleared.
However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must
determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The
PCM stores information in memory on EVAP system purging from previous engine run or drive
cycles.
If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing
the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak
Detection Test without setting the temporary fault.
If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the
PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the
Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will
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Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2963
illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be
cleared.
FIGURE 6 SECTION 3
If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP
system between the LDP and the fuel tank. This is done by monitoring the time required for the
LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present,
the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP
solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each
pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the
PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run
again. If blockage is again detected, P1486 is stored, and the MIL is illuminated.
FIGURE 6 SECTION 4
After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First,
the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to
build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be
sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak
checking. The LDP reed switch does not close and open during rapid pumping because the
diaphragm does not travel through its full range during this part of the test.
FIGURE 6 SECTION 5
Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed
switch to close (diaphragm to drop) after the LDP solenoid is turned off.
If the switch does not close, or closes after a long delay, it means that the system does not have
any significant leakage and the EVAP Leak Detection Test is complete.
However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low
enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the
PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by
monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by
several LDP test cycles may repeat several times before the PCM judges that a leak is present.
When leaks are present, the LDP test cycle time will be inversely proportional to the size of the
leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test
cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present.
If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to
detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The
important point to remember is if a leak is again detected on the next EVAP Leak Detection Test,
the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is
detected during the next test, the temporary fault will be cleared.
DIAGNOSTIC TIPS
During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure
6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid
activity will stop. As each section of the test begins, it indicates that the previous section passed
successfully. By watching to see which tests complete, you can see if any conditions are present
that the PCM considers abnormal.
For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it
means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible
blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the
test. However, the PCM will assume that the system is already pressurized and skip the rapid
pump cycles.
Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections
may mask a leak condition.
Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would
end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking.
In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel
system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP
system test. If the purge solenoid cannot properly vent the system the LDP cannot properly
complete the test for P1486 and this fault can set due to pressure being in the EVAP system during
the test sequence.
Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak
because of excess vapor generation. Additionally, any source for additional vapor generation can
hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP
diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle
into a warm shop for testing or high ambient temperatures.
Fully plugged and partially plugged underhood vacuum lines have been known to set MIL
conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for
pinches or blockage before condemning components.
TEST EQUIPMENT
The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually
detecting leaks in the evaporative system and will take
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Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2964
the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator
to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke
includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful
when components have to be removed to determine the exact leak location. For detailed test
instructions, follow the operators manual packaged with the EELD.
IMPORTANT
Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable
Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB
Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2965
Leak Detection Pump: Service and Repair
REMOVAL
Leak Detection Pump
The Leak Detection Pump LDP. is located under the driver's side in the cast cradle under the
steering gear. 1.
Raise and support vehicle on a hoist.
Leak Detection Pump Connector Lock
2. Push locking tab on connector to unlock.
3. Push down on connector latch and pull connector from pump.
4. Remove hoses.
5. Remove bolts holding LDP and bracket to cradle.
6. Remove bracket from LDP.
INSTALLATION
1. Install LDP to bracket. 2. Install LDP and bracket to cradle. Torque bolts to 9.5-14 Nm (85-125
in. lbs.). Before installing hoses to LDP, make sure they are not cracked or
split. If a hose leaks, it will cause the Check Engine Lamp to illuminate.
3. Install hoses to LDP.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 2966
4. Plug electrical connector into LDP. 5. Push connector locking tab into place. 6. Using DRB scan
tool, verify proper operation of LDP.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Backpressure Transducer > Component Information > Description and Operation
EGR Backpressure Transducer: Description and Operation
ELECTRONIC EGR TRANSDUCER SOLENOID-PCM OUTPUT
EGR Solenoid
EGR Solenoid
EGR Solenoid
The electronic EGR transducer contains an electrically operated solenoid and a back-pressure
transducer. The PCM operates the solenoid. The PCM determines when to energize the solenoid.
Exhaust system back-pressure controls the transducer.
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Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Backpressure Transducer > Component Information > Description and Operation > Page 2971
When the PCM energizes the solenoid, vacuum does not reach the transducer. Vacuum flows to
the transducer when the PCM de-energizes the solenoid.
When exhaust system back-pressure becomes high enough, it fully closes a bleed valve in the
transducer. When the PCM de-energizes the solenoid and back-pressure closes the transducer
bleed valve, vacuum flows through the transducer to operate the EGR valve.
De-energizing the solenoid, but not fully closing the transducer bleed hole (because of low
back-pressure), varies the strength of vacuum applied to the EGR valve. Varying the strength of
the vacuum changes the amount of EGR supplied to the engine. This provides the correct amount
of exhaust gas recirculation for different operating conditions.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations
EGR Control Solenoid: Locations
EGR Solenoid
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations > Page 2975
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Tube > Component Information > Specifications
EGR Tube: Specifications
EGR Tube to Intake Manifold Screws 22 Nm
EGR Tube Mounting Bolts 22 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Tube > Component Information > Specifications > Page 2979
EGR Tube: Service and Repair
REMOVAL
EGR Tube
1. Remove EGR tube attaching bolts from intake and exhaust manifolds. 2. Clean intake and
exhaust manifold gasket surfaces. Discard old gasket. 3. Check for signs of leakage or cracked
surfaces on either manifolds or tube. Repair or replace as necessary.
INSTALLATION
1. Loosely assemble EGR tube and new gaskets into place on intake and exhaust manifolds. 2.
Tighten mounting bolts to 22 Nm (200 in. lbs.) torque.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Specifications
EGR Valve: Specifications
EGR Valve Bolts 22 Nm
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Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Specifications > Page 2983
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Testing and Inspection > EGR Valve Leakage Test
EGR Valve: Testing and Inspection EGR Valve Leakage Test
This is not to be used as a complete test of the EGR system.
EGR Valve And EGR Valve - Typical
If the engine will not idle, dies out on idle, or idle is rough or slow, the poppet valve at the base of
the EGR valve may be leaking in the closed position.
1. The engine should be off for the following test. 2. Disconnect the rubber hose from the fitting at
the top vacuum motor. side of the EGR valve.
a. Connect a hand-held vacuum pump to this fitting. b. Apply 15 inches of vacuum to the pump. c.
Observe the gauge reading on the pump. d. If vacuum falls off, the diaphragm in the EGR valve
has ruptured. e. Replace the EGR valve. Note: The EGR valve, valve control and attaching hoses
are serviced as one assembly. Refer to EGR Valve
Removal/installation.
f. Proceed to the next step.
3. A small metal fitting back-pressure fitting. is located at the base of the EGR valve. A rubber
back-pressure hose connects it to the back-pressure
fitting on the EGR valve control. Disconnect this rubber hose at the EGR valve fitting.
4. Remove the air cleaner housing from the throttle body. 5. Using compressed air, and using an
air nozzle with a rubber tip, apply approximately 50 psi of regulated shop air to the metal
back-pressure fitting
on the EGR valve.
6. By hand, open the throttle to the wide open position. Air SHOULD NOT BE HEARD emitting
from the intake manifold while applying air
pressure at the back-pressure fitting.
7. If air CAN BE HEARD emitting from the intake manifold, the poppet valve is leaking at the
bottom of the EGR valve. Replace the EGR valve.
Note: The EGR valve, valve control and attaching hoses are serviced as one assembly. Refer to
EGR Valve Removal/installation. Do not attempt clean the old EGR valve.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Testing and Inspection > EGR Valve Leakage Test > Page 2986
EGR Valve: Testing and Inspection EGR Valve Control (Transducer) Test
Testing electrical solenoid portion of valve
This is not to be used as a complete test of the EGR system. Electrical operation of the valve
should be checked with the DRB scan tool. Refer to the appropriate Powertrain Diagnostic
Procedures service manual for operation of the DRB scan tool. Replace solenoid if necessary, unit
serviced only as an assembly.
Testing vacuum transducer portion of valve
The first part of this test will determine if the transducer diaphragm at the back-pressure side of the
valve has ruptured or is leaking. The second part of the test will determine if engine vacuum
full-manifold. is flowing from the inlet to the outlet side of the valve. This is not to be used as a
complete test of the EGR system.
EGR Valve And EGR Valve - Typical
1. Disconnect the rubber back-pressure hose from the fitting at the bottom of EGR valve. 2.
Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If
vacuum falls off, the valve diaphragm is leaking. 5. Replace the Complete EGR valve assembly.
Proceed to next step for further testing. 6. Reconnect hose to EGR valve. 7. Remove the vacuum
supply hose at the vacuum inlet fitting on the EGR solenoid. 8. Connect a vacuum gauge to this
disconnected vacuum line. 9. Start the engine and bring to operating temperature. Hold engine
speed at approximately 1500 rpm.
10. Check for steady engine vacuum full-manifold. at this hose. 11. If engine vacuum full-manifold.
is not present, check vacuum line to engine and repair as necessary before proceeding to next
step. 12. Reconnect the rubber hose to the vacuum inlet fitting on the EGR valve. 13. Disconnect
the rubber hose at the vacuum outlet fitting on the EGR valve. 14. Connect a vacuum gauge to this
fitting. 15. Disconnect the electrical connector at the valve control. This will simulate an open circuit
no ground from the PCM. at the valve, activating the
valve. A DTC will be set in the PCM that must be erased after testing is complete.
16. Start the engine and bring to operating temperature. 17. Hold the engine speed to
approximately 2000 rpm while checking for engine vacuum (full-manifold) at this fitting. To allow full
manifold vacuum
to flow through the valve, exhaust back-pressure must be present at valve. It must be high enough
to hold the bleed valve in the transducer portion of the valve closed. Have a helper momentarily a
second or two. hold a rag over the tailpipe opening to build some exhaust back-pressure while
observing the vacuum gauge. Heavy gloves should be worn. Do not cover the tailpipe opening for
an extended period of time as damage to components or overheating may result.
18. As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum
outlet fitting. Without back-pressure, and engine at
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Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Testing and Inspection > EGR Valve Leakage Test > Page 2987
approximately 2000 rpm, the gauge reading will be low. This low reading is normal. At idle speed,
the gauge reading may be erratic. This is also normal.
19. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting,
replace the valve. Note: The EGR valve, valve control
and attaching hoses are serviced as one assembly. Refer to EGR Valve Removal/installation.
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Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Testing and Inspection > Page 2988
EGR Valve: Service and Repair
The EGR valve and Electrical EGR Transducer are serviced as an assembly.
REMOVAL
EGR System
1. Disconnect vacuum tube from electric EGR transducer. Inspect vacuum tube for damage. 2.
Remove electrical connector from solenoid. 3. Remove EGR valve bolts from intake manifold. 4.
Open EGR transducer clip and remove electric EGR transducer. 5. Remove EGR valve from intake
manifold. 6. Clean gasket surface and discard old gasket. Check for any signs of leakage or
cracked surfaces. Repair or replace as necessary.
INSTALLATION
1. Assemble EGR valve with new gasket onto the intake manifold. 2. Install mounting bolts. Tighten
bolts to 22 Nm (200 in. lbs.) torque. 3. Install electric EGR transducer in clip with orientation tab in
slot and snap closed. 4. Reconnect vacuum hose and electrical connector to electrical EGR
transducer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Crankcase Filter > Component Information > Description and Operation
Crankcase Filter: Description and Operation
OPERATION
All engines use filtered air to vent the crankcase. The filtered air is drawn through the resonator
assembly located between the air cleaner and throttle body.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Description and Operation
Positive Crankcase Ventilation Valve: Description and Operation
OPERATION
The PCV valve contains a spring loaded plunger. The plunger meters the amount of crankcase
vapors routed into the combustion chamber based on intake manifold vacuum.
Engine Off Or Engine Backfire-No Vapor Flow
When the engine is not operating or during an engine backfire, the spring forces the plunger back
against the seat. This prevents vapors from flowing through the valve.
High Intake Manifold Vacuum-Minimal Vapor Flow
When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold
vacuum is able to completely compress the spring and pull the plunger to the top of the valve. In
this position there is minimal vapor flow through the valve.
Moderate Intake Manifold Vacuum-Maximum Vapor Flow
During periods of moderate intake manifold vacuum the plunger is only pulled part way back from
the inlet. This results in maximum vapor flow through the valve.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Page 2996
Positive Crankcase Ventilation Valve: Testing and Inspection
WARNING: APPLY PARKING BRAKE AND/OR BLOCK WHEELS BEFORE PERFORMING ANY
TEST OR ADJUSTMENT WITH THE ENGINE OPERATING.
PCV Test-Typical
With the engine idling, remove the PCV valve from its attaching point. If the valve is operating
properly, a hissing noise will be heard and a strong vacuum felt when placing a finger over the
valve inlet. With the engine off, shake the valve. The valve should rattle when shaken. Replace the
valve if it does not operate properly. Do not attempt to clean the PCV valve.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Specifications > Pressure, Vacuum and Temperature Specifications
Fuel Pressure: Pressure, Vacuum and Temperature Specifications
Fuel Pressure
Key On, Engine Off ..............................................................................................................................
......................................... (approx.) 338 kPa (49 psi)
Note: Using the DRB Scan Tool, access ASD Fuel System Test. The ASD Fuel System Test will
activate the fuel pump and pressurize the system.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain
energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off
position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System
Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3002
Fuel Pressure: Capacity Specifications
Information not supplied by the manufacturer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions > Page 3006
Fuel Pressure Release: Service and Repair
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap.
Fuel Pressure Test Port
Releasing Fuel Pressure
3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel
pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other
end of hose C-4799-1 to
fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container.
Fuel gauge C-4799-B contains hose C-4799-1.
5. Replace Pressure test port cap when finished doing pressure test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications
Idle Speed: Specifications
Minimum Air Flow Idle Odometer <= 1000 Miles .................................................................................
.................................................................................................. 525-875 rpm Odometer >= 1000
Miles ....................................................................................................................................................
............................... 575-875 rpm
Note: Idle speed range achieved through Minimum Air Flow Idle Test
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications > Page 3010
Idle Speed: Testing and Inspection
1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2.
Ensure that all accessories are off. 3. Shut off engine.
PCV Valve
4. Disconnect the PCV valve hose from the intake manifold nipple. 5. Cap the PCV valve nipple. 6.
Air Metering Fitting 6457
a. Install Air Metering Fitting 6457 (0.125 in. orifice) to the intake manifold PCV nipple. b.
Disconnect the idle purge line from the throttle body nipple.
7.
a. Cap the 3116 inch nipple. b. Connect the DRB scan tool to the data link connector.
8. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one
180°F cycle. 9. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen.
10. The following will then occur:
- Idle air control motor will fully close.
- Idle spark advance will become fixed.
- DRB scan tool displays engine rpm.
11. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum
air-flow is set correctly.
IDLE SPECIFICATION Odometer Reading = Idle RPM Below 1000 Miles = 525-875 RPM Above
1000 Miles = 575-875 RPM
12. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows:
a. Remove the throttle body from engine.
WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR
BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES
OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING
CLEANER.
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications > Page 3011
b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle body.
c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and
manifold side of the throttle blade. The edges of the
throttle blade and portions of the throttle bore that are closest to the throttle blade when closed,
must be free of deposits.
d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f.
Install throttle body on manifold.
g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is
not caused by the throttle body.
13. Shut off engine. 14. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple.
Reinstall the PCV valve hose. 15. Uncap the throttle body idle purge nipple and connect the idle
purge line. 16. Remove DRB scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications
Accelerator Pedal: Specifications
Accelerator Pedal Retaining Nuts 12 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications > Page 3015
Accelerator Pedal: Service Precautions
CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not
damage or kink the core wire inside the cable sheathing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications > Page 3016
Accelerator Pedal: Service and Repair
CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not
damage or kink the core wire inside the cable sheathing.
REMOVAL
1. Working from the engine compartment, remove the throttle control shield. 2. Hold the throttle
body throttle lever in the wide open position. Remove the throttle cable from the throttle body cam.
Accelerator Pedal And Throttle Cable-Front View
Accelerator Pedal And Throttle Cable-Rear View
3. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from
the upper end of the pedal shaft. 4. Working from the engine compartment, remove nuts from
accelerator pedal attaching studs. Remove assembly from vehicle.
INSTALLATION
1. Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts
to 12 Nm (105 in. lbs.) torque. 2. From inside the vehicle, hold up the pedal and install the throttle
cable and cable retainer in the upper end of the pedal shaft. 3. From the engine compartment, hold
the throttle body lever in the wide open position and install the throttle cable. Install the throttle
control shield.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
REMOVAL
Air Inlet Resonator
1. Remove 2 screws and air inlet resonator. 2. Loosen 3 clamps holding air cleaner housing halves
together.
Air Cleaner Housing (Left Side)
3. Remove left side of air cleaner housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 3021
Air Cleaner Element
4. Remove element from air cleaner housing.
INSTALLATION
1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4.
Install hoses and air inlet resonator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Specifications
Fuel: Specifications Fuel Rating
Fuel Rating
Fuel Unleaded fuel having a minimum octane rating of 87.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Specifications > Page 3025
Fuel: Service Precautions
CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic
converter and affect the warranty coverage validity.
CAUTION: DO NOT use gasoline containing methanol.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service Precautions > Page 3030
Fuel Pressure Release: Service and Repair
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM
COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION
SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap.
Fuel Pressure Test Port
Releasing Fuel Pressure
3. Remove protective cap from fuel pressure test port on fuel rail. 4. Place open end of fuel
pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other
end of hose C-4799-1 to
fuel pressure test port. Fuel pressure will bleed off through the hose into the gasoline container.
Fuel gauge C-4799-B contains hose C-4799-1.
5. Replace Pressure test port cap when finished doing pressure test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component
Information > Specifications
Fuel Hose Clamp: Specifications
Fuel Hose Clamps 1 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component
Information > Specifications > Page 3034
Fuel Hose Clamp: Service Precautions
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE
ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE
FUEL SYSTEM PRESSURE MUST BE RELEASED
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component
Information > Specifications > Page 3035
Fuel Hose Clamp: Description and Operation
FUEL TUBES/LINES/HOSES AND CLAMPS
Also refer to Quick-Connect Fittings.
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE
ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE
FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE.
Inspect all hose connections such as clamps, couplings and fittings to make sure they are secure
and leaks are not present. The component should be replaced immediately if there is any evidence
of degradation that could result in failure.
Never attempt to repair a plastic fuel line/tube. Replace as necessary.
Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes are properly routed to prevent pinching and to
avoid heat sources.
The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to
the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to
replace these lines/tubes/hoses, only those marked EFM/EFI may be used.
If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a
special rolled edge construction. This construction is used to prevent the edge of the clamp from
cutting into the hose. Only these rolled edge type clamps may be used in this system. All other
types of clamps may cut into the hoses and cause high-pressure fuel leaks.
Use new original equipment type hose clamps. Tighten hose clamps to 3 Nm (25 in. lbs.) torque.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component
Information > Specifications > Page 3036
Fuel Hose Clamp: Testing and Inspection
Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks.
Replace cracked, scuffed, or swelled hoses. Replace hoses that rub against other vehicle
components or show sign of wear.
Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses
marked EFM/EFI.
When installing hoses, ensure that they are routed away from contact with other vehicle
components that could rub against them and cause failure. Avoid contact with clamps or other
components that cause abrasions or scuffing. Ensure that rubber hoses are properly routed and
avoid heat sources.
The hose clamps have rolled edges to prevent the clamp from cutting into the hose. Only use
clamps that are original equipment or equivalent. Other types of clamps may cut into the hoses and
cause high pressure fuel leaks, Tighten hose clamps to 1 Nm (10 in. lbs.) torque.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications
Fuel Injector: Electrical Specifications
Injector Resistance ..............................................................................................................................
.......................................... 12 ohms at 20 ° C (68 ° F)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications > Page 3041
Fuel Injector: Pressure, Vacuum and Temperature Specifications
Information not supplied by the manufacturer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3042
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3043
Fuel Injector: Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3044
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3045
Fuel Injector: Description and Operation
DESCRIPTION
Fuel Injector Location - Typical
The injectors are positioned in the intake manifold with the nozzle ends directly above the intake
valve port.
OPERATION
Fuel Injector
The fuel injectors are 12 ohm electrical solenoids. The injector contains a pintle that closes off an
orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle
move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is
under high pressure, a fine spray is developed in the shape of a hollow cone. The spraying action
atomizes the fuel, adding it to the air entering the combustion chamber. Fuel injectors are not
interchangeable between engines.
Fuel Injector
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3046
FUEL INJECTORS-PCM OUTPUT
The fuel injectors are 12 ohm electrical solenoids. The injector contains a pintle that closes off an
orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle
move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is
under high pressure, a fine spray is developed in the shape of a hollow cone. The spraying action
atomizes the fuel, adding it to the air entering the combustion chamber. The injectors are
positioned in the intake manifold.
Fuel Injector Location-Typical
The injectors are positioned in the intake manifold with the nozzle ends directly above the intake
valve port.
The fuel injectors are operated by the PCM. They are energized in a sequential order during all
engine operating conditions except start up. The PCM initially energizes all injectors at the same
time. Once PCM determines crankshaft position, it begins energizing the injectors in sequence.
The Automatic Shutdown (ASD) relay supplies battery voltage to the injectors. The PCM provides
the ground path for the injectors. By switching the ground path on and off, the PCM adjusts injector
pulse width. Pulse width is the amount of time the injector is energized. The PCM adjusts injector
pulse width based on inputs it receives.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3047
Fuel Injector: Testing and Inspection
Fuel Injector Diagnosis
For fuel injector diagnosis, refer to the Fuel Injector Diagnosis charts.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3048
Fuel Injector: Service and Repair
The fuel rail must be removed first. Refer to Fuel Injector Rail Assembly Removal.
REMOVAL
1. Disconnect injector wiring connector from injector.
Fuel Injector And Rail-Typical
2. Position fuel rail assembly so that the fuel injectors are easily accessible. 3. Rotate injector and
pull injector out of fuel rail. The clip will stay on the injector. 4. Check injector O-ring for damage. If
O-ring is damaged, it must be replaced. If injector is reused, a protective cap must be installed on
the injector
tip to prevent damage. Replace the injector clip if it is damaged.
5. Repeat for remaining injectors.
INSTALLATION
1. Before installing an injector the rubber O-ring must be lubricated with a drop of clean engine oil
to aid in installation.
Servicing Fuel Injector - Typical
2. Install injector clip by sliding open end into the top slot of the injector. The edge of the receiver
cup will slide into the side slots of clip. 3. Install injector top end into fuel rail receiver cap. Be
careful not to damage O-ring during installation. 4. Repeat steps for remaining injectors. 5. Connect
fuel injector wiring.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service Precautions
Fuel Line Coupler: Service Precautions
WARNING:
- RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT
FITTINGS.
- THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
CAUTION:
- Never install a quick-connect fitting without the retainer being either on the fuel tube or already in
the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect
fitting by firmly pulling on fuel tube and fitting to ensure it is secured.
- The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced
separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel
lines/tubes. If repair is necessary, replace the complete fuel tube assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service Precautions > Page 3052
Fuel Line Coupler: Description and Operation
QUICK-CONNECT FITTINGS
DESCRIPTION Different types of quick-connect fittings are used to attach various fuel system
components. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are
equipped with safety latch clips. Refer to the Removal/installation for more information.
CAUTION: The interior components (O-rings, spacers) of quick-connect fitting are not serviced
separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary,
replace the complete fuel tube assembly.
Plastic Quick-Connect Fittings
Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting
contains non-serviceable O-ring seals.
CAUTION: Quick-connect fittings are not serviced separately. Do not attempt to repair damaged
quick- connect fittings or fuel tubes. Replace the complete fuel tube/quick-connect fitting assembly.
The quick-connect fitting consists of the O-rings, retainer and casing. When the fuel tube enters the
fitting, the retainer locks the shoulder of the nipple in place and the O-rings seal the tube.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service Precautions > Page 3053
Fuel Line Coupler: Service and Repair
REMOVAL
When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A
QUICK-CONNECT FITTINGS. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE.
1. Disconnect negative cable from battery or auxiliary jumper terminal. 2. Perform Fuel Pressure
Release Procedure. Refer to the Fuel Pressure Release Procedure. 3. Squeeze retainer tabs
together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will
remain on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case, ensure the retainer locks securely into the
quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured.
1. Using a clean lint free cloth, clean the fuel tube nipple and retainer. 2. Prior to connecting the
fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil. 3. Push the
quick-connect fitting over the fuel tube until the retainer seats and a click is heard.
Plastic Quick-Connect Fitting/Fuel Tube Connection
4. The plastic quick-connect fitting has windows in the sides of the casing. When the fitting
completely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the windows. If they are not visible, the retainer was
not properly installed. Do not rely upon the audible click to confirm a secure connection.
5. Connect negative cable to battery or auxiliary jumper terminal.
CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains
energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the
Off position.
6. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
TWO-TAB TYPE FITTING
Typical Two-Tab Type Quick-Connect Fitting
This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied
for disconnecting the quick-connect fitting from component being serviced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service Precautions > Page 3054
CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not
serviced separately, but new plastic retainers are available. Do not attempt to repair damaged
fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE
ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE
FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE
RELEASE PROCEDURE.
Disconnection/Connection 1. Perform fuel pressure release procedure. Refer to Fuel Pressure
Release Procedure. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal.
3. Clean fitting of any foreign material before disassembly. 4. To disconnect quick-connect fitting,
squeeze plastic retainer tabs against sides of quick-connect fitting with your fingers. Tool use is not
required
for removal and may damage plastic retainer. Pull fitting from fuel system component being
serviced. The plastic retainer will remain on component being serviced after fitting is disconnected.
The O-rings and spacer will remain in quick-connect fitting connector body.
5. Inspect quickconnect fitting body and component for damage. Replace as necessary.
CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the
component being serviced. If this retainer must be removed, very carefully release the retainer from
the component with two small screwdrivers. After removal, inspect the retainer for cracks or any
damage.
6. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
7. Insert quick-connect fitting to component being serviced and into plastic retainer. When a
connection is made, a click will be heard. 8. Verify a locked condition by firmly pulling on fuel tube
and fitting (15-30 lbs.). 9. Connect negative cable to battery or auxiliary jumper terminal.
10. Start engine and check for leaks,
PLASTIC RETAINER RING TYPE FITTING
Plastic Retainer Ring Type Fitting
This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in
color.
CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is
necessary, replace the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE
ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE
FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM
PRESSURE RELEASE PROCEDURE.
Disconnection/Connection 1. Perform fuel pressure release procedure. Refer to Fuel Pressure
Release Procedure. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal.
3. Clean fitting of any foreign material before disassembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service Precautions > Page 3055
4. To release fuel system component from quick-connect fitting, firmly push fitting towards
component being serviced while firmly pushing plastic
retainer ring into fitting. With plastic ring depressed, pull fitting from component. The plastic retainer
ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be
difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in
disconnection.
5. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. 6.
Inspect fitting connector body, plastic retainer ring and fuel system component for damage.
Replace as necessary. 7. Prior to connecting quick-connect fitting to component being serviced,
check condition of fitting and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
8. Insert quick-connect fitting into component being serviced until a click is felt. 9. Verify a locked
condition by firmly pulling on fuel tube and fitting (15-30 lbs.).
10. Connect negative battery cable to battery or auxiliary jumper terminal. 11. Start engine and
check for leaks.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Service Precautions
Fuel Pressure Regulator: Service Precautions
WARNING: FUEL SYSTEM PRESSURE MUST BE RELEASED BEFORE SERVICING ANY FUEL
SYSTEM COMPONENT. PERFORM THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Service Precautions > Page 3059
Fuel Pressure Regulator: Description and Operation
OPERATION
The fuel system uses a nonadjustable pressure regulator that maintains fuel system pressure at
approximately 338 kPa (49 psi), 3.31 FFV uses approximately 379 kPa (55 psi). The fuel pressure
regulator contains a diaphragm, calibrated spring and a fuel return valve. The spring pushes down
on the diaphragm and closes off the fuel return port. System fuel pressure reflects the amount of
fuel pressure required to open the return port.
The pressure regulator is a mechanical device that is NOT controlled by the PCM or engine
vacuum.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Service Precautions > Page 3060
Fuel Pressure Regulator: Service and Repair
Fuel Pressure Regulator
The fuel pressure regulator is part of the fuel pump module. Remove the fuel pump module from
the fuel tank to access the fuel pressure regulator. Refer to the Fuel Pump Module removal.
WARNING: FUEL SYSTEM PRESSURE MUST BE RELEASED BEFORE SERVICING ANY FUEL
SYSTEM COMPONENT. PERFORM THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE.
REMOVAL
1. Spread tangs on pressure regulator retainer. 2. Pry fuel pressure regulator out of housing. 3.
Ensure both upper and lower O-rings were removed with regulator.
INSTALLATION
Fuel Pressure Regulator O-rings
1. Lightly lubricate the O-rings with clean engine oil and place them into opening in pump module.
2. Push regulator into opening in pump module. 3. Fold tangs on regulator retainer over tabs on
housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Pressure, Vacuum and Temperature Specifications
Fuel Pressure: Pressure, Vacuum and Temperature Specifications
Fuel Pressure
Key On, Engine Off ..............................................................................................................................
......................................... (approx.) 338 kPa (49 psi)
Note: Using the DRB Scan Tool, access ASD Fuel System Test. The ASD Fuel System Test will
activate the fuel pump and pressurize the system.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain
energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off
position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Pressure, Vacuum and Temperature Specifications > Page 3066
Fuel Pressure: Capacity Specifications
Information not supplied by the manufacturer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations
Fuel Pump Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3070
Power Distribution Center -- Sheet 8w-10-2
The fuel pump relay is located in the PDC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3071
Fuel Pump Relay: Diagrams
Power Distribution Center
Fuel Pump Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3072
Fuel Pump Relay: Description and Operation
FUEL PUMP RELAY-PCM OUTPUT
The fuel pump relay supplies battery voltage to the fuel pump. The fuel pump relay power circuit
contains a 9 amp fuse. The fuse is located in the PDC.
The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the
relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position.
When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft
position sensor does not detect engine rotation, the PCM de-energizes the relay after
approximately one second.
The fuel pump relay is located in the PDC. A label affixed to the underside of the PDC cover
identifies the relays and fuses in the PDC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3073
Fuel Pump Relay: Testing and Inspection
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3074
terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter >
Component Information > Service and Repair
Fuel Pump Pickup Filter: Service and Repair
REMOVAL
1. Remove fuel pump module. Refer to Fuel Pump Module Removal.
Inlet Strainer Removal
2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and
remove the strainer. 3. Remove strainer O-ring from the fuel pump reservoir body. 4. Remove any
contaminants in the fuel tank by washing the inside of the fuel tank.
INSTALLATION
1. Lubricate the strainer O-ring with clean engine oil. 2. Insert strainer O-ring into outlet of strainer
so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump
reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the
strainer.
4. Install fuel pump module. Refer to Fuel Pump Module Installation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage
Technical Service Bulletin # 895 Date: 020101
Recall - Potential Fuel Rail Seal Leakage
January 2002
Dealer Service Instructions for
Safety Recall No. 895 -- Fuel Rail Seals
Models
1996-2000 (NS) Dodge Caravan/Grand Caravan; Plymouth Voyager/Grand Voyager and Chrysler
Town & Country
NOTE:
This recall applies only to the above vehicles equipped with a 3.3L or 3.8L gasoline engine ("R" or
"L" in the 8 VIN Position) through Engine Build Date - 102389 (August 26, 1999).
IMPORTANT:
Vehicles equipped with a 3.3L Flex Fuel engine ("G" in the 8th VIN position) are NOT involved in
this recall.
IMPORTANT:
Vehicles that already had a fuel rail with the proper O-rings installed, according to Warranty
records, have been excluded from this recall.
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.
Subject
After extended use, the fuel rail crossover tube 0-rings on about 1,136,000 of the above vehicles
may leak fuel. Fuel leakage in the presence of an ignition source can result in an engine
compartment fire.
Repair
External seals must be installed at both of the fuel rail crossover tube joints. If the crossover tube
joints are leaking or red rust exists in the area, the fuel rail assembly must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3086
Parts Information
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3087
Use one of the labor operation numbers and time allowances shown.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required
Dealer Notification
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as
needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD895".
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are
identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by describing the reason on a postcard and mail
to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Customer Services Field Operations DaimlerChrysler Corporation
A. Inspect Fuel Rail
1. Raise hood.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3088
2. Inspect both of the fuel rail crossover tube joints (Figure 1)
3. > If there are signs of fuel leakage from either of the fuel rail crossover tube joints, the fuel rail
assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly.
> If there are signs of RED rust near either of the fuel rail crossover tube joints, the fuel rail
assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly.
If there are NO indications of fuel leakage OR RED rust near either of the fuel rail crossover tube
joints, continue with Section B - Install Fuel Rail Seals.
B. Install Fuel Rail Seals
1. If the engine is equipped with an intake manifold cover (1996 and early-1997 3.8L engines only),
remove the cover and set it aside.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3089
2. Using the provided Scotch-Brite pad, clean any dirt or white oxide build-up from the fuel rail area
near the crossover tube joints (Figure 2). Clean both of the crossover tube joints with the
Scotch-Brite pad and then use compressed air to remove any remaining particles.
3. Install the two provided clamps around the crossover tube. Start the clamps for 1-2 turns to ease
seal installation.
4. Lightly lubricate the rubber material of the four fuel rail seal halves with clean engine oil. Be sure
to coat the flat ends as well as the two beads.
IMPORTANT:
Drain any excess oil from the seals.
5. Install two of the seal halves around the front fuel rail crossover tube joint (Figure 3).
NOTE:
Both of the seal halves are identical.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3090
6. Seat the seal halves around the joint and then while holding the two seals halves together, install
one of the provided clamps around the seal halves (Figure 4).
7. Tighten the clamp to 75 in-lbs (8.5 N.m).
8. Install the remaining two seal halves around the rear fuel rail crossover tube joint (Figure 3).
9. Seat the seal halves around the joint and then while holding the two seals halves together, install
the other clamp around the seal halves (Figure 4).
10. Tighten the clamp to 75 in-lbs (8.5 N.m).
11. If the engine was equipped with an intake manifold cover (1996 and early-1997 3.8L only), the
cover must be modified as follows:
a. Remove the spring clip from the cover that was attached to the fuel rail near the crossover tube
joint (Figure 5). Discard the clip.
b. Using a small cut-off wheel, saw or similar tool, remove the plastic cover material inside of the
mold line on the end of the cover (Figure 5).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3091
c. Reinstall the cover onto the intake manifold. Tighten the cover bolt securely.
12. No further action is necessary. Return the vehicle to the customer.
C. Replace Fuel Rail Assembly
NOTE:
Only fuel rails with fuel leakage or RED rust at the crossover tube joint, as determined by the
inspection in Section A, require replacement. Very few vehicles are expected to require fuel rail
replacement.
WARNING:
The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be
released before replacing the fuel rail.
1. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure.
3. Remove the protective cap from the pressure test port on the fuel rail (Figure 6).
WARNING:
Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and
around the pressure port to absorb fuel when pressure is released from the rail.
4. Obtain the hose from the fuel pressure gauge tool set # C-4799-1 Position one end of the hose
into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel
pressure.
5. Remove the hose from the fuel rail and reinstall the test port cap.
6. Remove the plastic intake manifold cover, if equipped.
7. Remove the air inlet resonator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3092
8. Remove the throttle cable and speed control cable (if equipped) from the throttle lever and
bracket (Figure 7).
9. Disconnect the idle air control motor and Throttle Position Sensor (TPS) electrical connectors
(Figure 8).
10. Disconnect the vacuum hoses from the throttle body and intake manifold (Figure 9).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3093
11. Disconnect the EGR tube from the intake manifold flange (Figure 10).
12. Disconnect the cylinder head-to- intake plenum strut from the cylinder head.
13. Disconnect the MAP sensor electrical connector (Figure 11).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3094
14. Disconnect the fuel hose quick connect fitting from the chassis fuel tube (Figure 12).
WARNING:
Wrap a shop towel around the hoses to catch any gasoline spillage.
15. Remove the Direct Ignition System (DIS) coil pack (Figure 13).
16. Remove the generator support bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3095
17. Remove the intake plenum mounting bolts and rotate the plenum back over the rear valve
cover (Figure 14).
NOTE:
It is not necessary to completely remove the intake plenum from the vehicle.
18. Cover the intake manifold openings.
19. Remove the fuel rail attaching bolts (Figure 15).
20. Disconnect the engine coolant temperature sensor and camshaft position sensor or coil pack
electrical connectors (Figure 16).
21. Disconnect the fuel rail wiring harness from the main engine harness.
22. Remove the fuel rail assembly.
23. Position the fuel rail on a clean bench or other suitable work surface so that the fuel injectors
are easily accessible.
24. Disconnect the injector wiring connectors from the fuel injectors and then remove the wiring
harness from the fuel rail.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3096
25. Rotate the injectors and then pull them out of the fuel rail. The injector clip will stay on the
injector (Figure 17).
26. Remove the upper and lower injector 0-rings from the injectors.
27. Lubricate the new upper 0-rings (BLUE) with a drop of clean engine oil.
28. Install the new upper 0-rings (BLUE) on the top of the injectors.
CAUTION:
Do NOT install the black 0-rings in the upper 0-ring position or fuel leakage may result.
29. Lubricate the new lower 0-rings (BLACK) with a drop of clean engine oil.
30. Install the new lower 0-rings (BLACK) on the bottom of the injectors.
31. Install the injector clips onto the injectors, if necessary, by sliding the open end into the top slot
of the injector.
32. Install the injectors into the new fuel rail (Figure 17). Make sure that the injector clips are fully
seated. Use care so that the upper 0-ring is not damaged during installation.
33. Connect the injector wiring harness to the injectors.
34. Put the tip of each injector into its port in the intake manifold and then gently push the fuel rail
assembly into place until all injectors are seated in their port.
35. In stall the fuel rail mounting bolts (Figure 15). Tighten the mounting bolts to 200 in-lbs (22
N.m).
36. Connect the fuel injector wiring harness to the main engine wiring harness.
37. Connect the fuel rail hose quick connect fitting to the chassis fuel tube (Figure 12). Push the
connector on until it clicks and then pull back to ensure a complete connection.
38. Connect the coolant temperature sensor and camshaft position sensor or coil pack electrical
connectors (Figure 16).
39. Remove the covering from the intake manifold openings. Clean the intake manifold and intake
plenum gasket surfaces.
40. Place the provided intake plenum gasket on the intake manifold.
41 Install the intake plenum onto the intake manifold (Figure 14) Loosely install the intake plenum
bolts. Do NOT tighten.
42. Install the generator bracket~ Loosely install the bracket bolts. Do NOT tighten.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3097
43. Install the cylinder head-to-intake plenum strut. Loosely install the strut mounting bolt. Do NOT
tighten.
44. Using the supplied gasket, connect the EGR tube to the intake plenum (Figure 10). Loosely
install the mounting bolts. Do NOT tighten.
45. Following the tightening sequence in Figure 14, tighten the intake plenum bolts to 250 in-lbs (28
N.m).
46. Tighten the generator bracket bolts to 40 ft-lbs (54 N.m).
47. Tighten the cylinder head-to-intake plenum strut bolt to 40 ft-lbs (54 N.m).
48. Tighten the EGR tube bolts to 200 in-lbs (22 N.m) (Figure 10).
49. Install the DIS coil pack (Figure 13). Tighten the bolts to 105 in-lbs (12 Nm).
50. Connect the MAP sensor electrical connector (Figure 11).
51. Connect the vacuum hoses to the intake plenum (Figure 9).
52. Connect the TPS and idle air control motor electrical connectors (Figure 8).
53. Connect the throttle body vacuum connectors (Figure 9).
54. Connect the throttle cable and speed control cable (if equipped) (Figure 7).
55. Install the intake manifold cover (if equipped).
56. Install the air inlet resonator.
57. Connect the negative battery cable.
58. Start the engine and check for any fuel leakage.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3098
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > NHTSA00V268000 > Sep > 00 > Recall 00V268000:
Fuel Rail Cracks/Leaks
Fuel Rail: Recalls Recall 00V268000: Fuel Rail Cracks/Leaks
Mini vans built with 3.3L and 3.8L engines. The fuel injection delivery system can leak fuel from
some of the sealing O-rings or from hair line cracks in the thermoset fuel injection rail.
Fuel leakage in the presence of an ignition source can result in a fire.
Dealers will install a seal on the vehicle fuel rails to prevent external leakage of fuel from the fuel
rail crossover tube, should the existing O-rings continue to degrade.
DaimlerChrysler has not yet provided NHTSA with an owner notification schedule.
However, if a vehicle is leaking fuel from the O-rings or from a cracked fuel line, the vehicle should
be taken into a dealer to have this repaired as soon as possible. Owners who take their vehicles to
an authorized dealer on an agreed upon service date and do not receive the free remedy within a
reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National
Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT
(1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage
Technical Service Bulletin # 895 Date: 020101
Recall - Potential Fuel Rail Seal Leakage
January 2002
Dealer Service Instructions for
Safety Recall No. 895 -- Fuel Rail Seals
Models
1996-2000 (NS) Dodge Caravan/Grand Caravan; Plymouth Voyager/Grand Voyager and Chrysler
Town & Country
NOTE:
This recall applies only to the above vehicles equipped with a 3.3L or 3.8L gasoline engine ("R" or
"L" in the 8 VIN Position) through Engine Build Date - 102389 (August 26, 1999).
IMPORTANT:
Vehicles equipped with a 3.3L Flex Fuel engine ("G" in the 8th VIN position) are NOT involved in
this recall.
IMPORTANT:
Vehicles that already had a fuel rail with the proper O-rings installed, according to Warranty
records, have been excluded from this recall.
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.
Subject
After extended use, the fuel rail crossover tube 0-rings on about 1,136,000 of the above vehicles
may leak fuel. Fuel leakage in the presence of an ignition source can result in an engine
compartment fire.
Repair
External seals must be installed at both of the fuel rail crossover tube joints. If the crossover tube
joints are leaking or red rust exists in the area, the fuel rail assembly must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3108
Parts Information
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3109
Use one of the labor operation numbers and time allowances shown.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required
Dealer Notification
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as
needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD895".
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are
identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by describing the reason on a postcard and mail
to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Customer Services Field Operations DaimlerChrysler Corporation
A. Inspect Fuel Rail
1. Raise hood.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3110
2. Inspect both of the fuel rail crossover tube joints (Figure 1)
3. > If there are signs of fuel leakage from either of the fuel rail crossover tube joints, the fuel rail
assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly.
> If there are signs of RED rust near either of the fuel rail crossover tube joints, the fuel rail
assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly.
If there are NO indications of fuel leakage OR RED rust near either of the fuel rail crossover tube
joints, continue with Section B - Install Fuel Rail Seals.
B. Install Fuel Rail Seals
1. If the engine is equipped with an intake manifold cover (1996 and early-1997 3.8L engines only),
remove the cover and set it aside.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3111
2. Using the provided Scotch-Brite pad, clean any dirt or white oxide build-up from the fuel rail area
near the crossover tube joints (Figure 2). Clean both of the crossover tube joints with the
Scotch-Brite pad and then use compressed air to remove any remaining particles.
3. Install the two provided clamps around the crossover tube. Start the clamps for 1-2 turns to ease
seal installation.
4. Lightly lubricate the rubber material of the four fuel rail seal halves with clean engine oil. Be sure
to coat the flat ends as well as the two beads.
IMPORTANT:
Drain any excess oil from the seals.
5. Install two of the seal halves around the front fuel rail crossover tube joint (Figure 3).
NOTE:
Both of the seal halves are identical.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3112
6. Seat the seal halves around the joint and then while holding the two seals halves together, install
one of the provided clamps around the seal halves (Figure 4).
7. Tighten the clamp to 75 in-lbs (8.5 N.m).
8. Install the remaining two seal halves around the rear fuel rail crossover tube joint (Figure 3).
9. Seat the seal halves around the joint and then while holding the two seals halves together, install
the other clamp around the seal halves (Figure 4).
10. Tighten the clamp to 75 in-lbs (8.5 N.m).
11. If the engine was equipped with an intake manifold cover (1996 and early-1997 3.8L only), the
cover must be modified as follows:
a. Remove the spring clip from the cover that was attached to the fuel rail near the crossover tube
joint (Figure 5). Discard the clip.
b. Using a small cut-off wheel, saw or similar tool, remove the plastic cover material inside of the
mold line on the end of the cover (Figure 5).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3113
c. Reinstall the cover onto the intake manifold. Tighten the cover bolt securely.
12. No further action is necessary. Return the vehicle to the customer.
C. Replace Fuel Rail Assembly
NOTE:
Only fuel rails with fuel leakage or RED rust at the crossover tube joint, as determined by the
inspection in Section A, require replacement. Very few vehicles are expected to require fuel rail
replacement.
WARNING:
The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be
released before replacing the fuel rail.
1. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure.
3. Remove the protective cap from the pressure test port on the fuel rail (Figure 6).
WARNING:
Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and
around the pressure port to absorb fuel when pressure is released from the rail.
4. Obtain the hose from the fuel pressure gauge tool set # C-4799-1 Position one end of the hose
into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel
pressure.
5. Remove the hose from the fuel rail and reinstall the test port cap.
6. Remove the plastic intake manifold cover, if equipped.
7. Remove the air inlet resonator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3114
8. Remove the throttle cable and speed control cable (if equipped) from the throttle lever and
bracket (Figure 7).
9. Disconnect the idle air control motor and Throttle Position Sensor (TPS) electrical connectors
(Figure 8).
10. Disconnect the vacuum hoses from the throttle body and intake manifold (Figure 9).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3115
11. Disconnect the EGR tube from the intake manifold flange (Figure 10).
12. Disconnect the cylinder head-to- intake plenum strut from the cylinder head.
13. Disconnect the MAP sensor electrical connector (Figure 11).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3116
14. Disconnect the fuel hose quick connect fitting from the chassis fuel tube (Figure 12).
WARNING:
Wrap a shop towel around the hoses to catch any gasoline spillage.
15. Remove the Direct Ignition System (DIS) coil pack (Figure 13).
16. Remove the generator support bracket.
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3117
17. Remove the intake plenum mounting bolts and rotate the plenum back over the rear valve
cover (Figure 14).
NOTE:
It is not necessary to completely remove the intake plenum from the vehicle.
18. Cover the intake manifold openings.
19. Remove the fuel rail attaching bolts (Figure 15).
20. Disconnect the engine coolant temperature sensor and camshaft position sensor or coil pack
electrical connectors (Figure 16).
21. Disconnect the fuel rail wiring harness from the main engine harness.
22. Remove the fuel rail assembly.
23. Position the fuel rail on a clean bench or other suitable work surface so that the fuel injectors
are easily accessible.
24. Disconnect the injector wiring connectors from the fuel injectors and then remove the wiring
harness from the fuel rail.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3118
25. Rotate the injectors and then pull them out of the fuel rail. The injector clip will stay on the
injector (Figure 17).
26. Remove the upper and lower injector 0-rings from the injectors.
27. Lubricate the new upper 0-rings (BLUE) with a drop of clean engine oil.
28. Install the new upper 0-rings (BLUE) on the top of the injectors.
CAUTION:
Do NOT install the black 0-rings in the upper 0-ring position or fuel leakage may result.
29. Lubricate the new lower 0-rings (BLACK) with a drop of clean engine oil.
30. Install the new lower 0-rings (BLACK) on the bottom of the injectors.
31. Install the injector clips onto the injectors, if necessary, by sliding the open end into the top slot
of the injector.
32. Install the injectors into the new fuel rail (Figure 17). Make sure that the injector clips are fully
seated. Use care so that the upper 0-ring is not damaged during installation.
33. Connect the injector wiring harness to the injectors.
34. Put the tip of each injector into its port in the intake manifold and then gently push the fuel rail
assembly into place until all injectors are seated in their port.
35. In stall the fuel rail mounting bolts (Figure 15). Tighten the mounting bolts to 200 in-lbs (22
N.m).
36. Connect the fuel injector wiring harness to the main engine wiring harness.
37. Connect the fuel rail hose quick connect fitting to the chassis fuel tube (Figure 12). Push the
connector on until it clicks and then pull back to ensure a complete connection.
38. Connect the coolant temperature sensor and camshaft position sensor or coil pack electrical
connectors (Figure 16).
39. Remove the covering from the intake manifold openings. Clean the intake manifold and intake
plenum gasket surfaces.
40. Place the provided intake plenum gasket on the intake manifold.
41 Install the intake plenum onto the intake manifold (Figure 14) Loosely install the intake plenum
bolts. Do NOT tighten.
42. Install the generator bracket~ Loosely install the bracket bolts. Do NOT tighten.
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3119
43. Install the cylinder head-to-intake plenum strut. Loosely install the strut mounting bolt. Do NOT
tighten.
44. Using the supplied gasket, connect the EGR tube to the intake plenum (Figure 10). Loosely
install the mounting bolts. Do NOT tighten.
45. Following the tightening sequence in Figure 14, tighten the intake plenum bolts to 250 in-lbs (28
N.m).
46. Tighten the generator bracket bolts to 40 ft-lbs (54 N.m).
47. Tighten the cylinder head-to-intake plenum strut bolt to 40 ft-lbs (54 N.m).
48. Tighten the EGR tube bolts to 200 in-lbs (22 N.m) (Figure 10).
49. Install the DIS coil pack (Figure 13). Tighten the bolts to 105 in-lbs (12 Nm).
50. Connect the MAP sensor electrical connector (Figure 11).
51. Connect the vacuum hoses to the intake plenum (Figure 9).
52. Connect the TPS and idle air control motor electrical connectors (Figure 8).
53. Connect the throttle body vacuum connectors (Figure 9).
54. Connect the throttle cable and speed control cable (if equipped) (Figure 7).
55. Install the intake manifold cover (if equipped).
56. Install the air inlet resonator.
57. Connect the negative battery cable.
58. Start the engine and check for any fuel leakage.
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3120
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > NHTSA00V268000 > Sep > 00 >
Recall 00V268000: Fuel Rail Cracks/Leaks
Fuel Rail: All Technical Service Bulletins Recall 00V268000: Fuel Rail Cracks/Leaks
Mini vans built with 3.3L and 3.8L engines. The fuel injection delivery system can leak fuel from
some of the sealing O-rings or from hair line cracks in the thermoset fuel injection rail.
Fuel leakage in the presence of an ignition source can result in a fire.
Dealers will install a seal on the vehicle fuel rails to prevent external leakage of fuel from the fuel
rail crossover tube, should the existing O-rings continue to degrade.
DaimlerChrysler has not yet provided NHTSA with an owner notification schedule.
However, if a vehicle is leaking fuel from the O-rings or from a cracked fuel line, the vehicle should
be taken into a dealer to have this repaired as soon as possible. Owners who take their vehicles to
an authorized dealer on an agreed upon service date and do not receive the free remedy within a
reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National
Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT
(1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Page 3125
Fuel Rail: Specifications
Fuel Rail Mounting Bolts 22 Nm
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Information > Technical Service Bulletins > Page 3126
Fuel Rail: Service and Repair
WARNING: THE MPI FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF
APPROXIMATELY 330 kPa (49 PSI), 3.3L USES APPROXIMATELY 379 kPa (55 PSI).
PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL RAIL
OR FUEL INJECTORS.
REMOVAL
1. Perform fuel system pressure release procedure. 2. Disconnect negative cable from battery. 3.
Remove intake manifold cover.
Air Inlet Resonator
4. Remove air inlet resonator.
Throttle Cable Attachment
5. Remove throttle cable and speed control cable (if equipped) from throttle lever and bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Information > Technical Service Bulletins > Page 3127
Electrical And Vacuum Connection To Throttle Body
6. Disconnect idle air control motor and Throttle Position Sensor (TPS) electrical connectors.
Vacuum Connections
7. Remove vacuum hose harness from throttle body and intake manifold.
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Information > Technical Service Bulletins > Page 3128
EGR Tube
8. Remove EGR tube to intake manifold flange bolts. 9. Remove cylinder head to intake plenum
strut.
Map Sensor
10. Disconnect electrical connector from the MAP sensor. 11. Remove engine mounted ground
strap.
Fuel Line Quick Disconnect
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Information > Technical Service Bulletins > Page 3129
12. Remove the fuel hose quick connect fitting from the chassis tube. Refer to Fuel Hoses, Clamps
and Quick Connect Fittings.
WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.
Ignition Coils
13. Remove Direct Ignition System (DIS) coils. 14. Remove generator bracket to intake manifold
bolt.
Intake Manifold Bolts
15. Remove intake mounting manifold bolts and rotate manifold back over rear valve cover.
Fuel Rail Attaching Bolts
16. Cover intake manifold with suitable cover when servicing.
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Information > Technical Service Bulletins > Page 3130
17. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread the retainer
bracket to allow fuel tube removal clearance.
Camshaft Position Sensor Connector
18. Disconnect camshaft position sensor and engine coolant temperature sensor.
Fuel Rail Removal
19. Remove fuel rail. Be careful not to damage the injector O-rings upon removal from their ports.
INSTALLATION
1. Ensure injector holes are clean. Replace O-rings if damaged. 2. Lubricate injector O-rings with a
drop of clean engine oil to ease installation. 3. Put the tip of each injector into their ports. Push the
assembly into place until the injectors are seated in the ports. 4. Install the fuel rail mounting bolts.
Tighten bolts to 22 Nm (200 in. lbs.) torque. 5. Install fuel tube retaining bracket screw. Tighten
screw to 4 Nm (35 in. lbs.) torque. 6. Connect electrical connectors to camshaft position sensor and
engine coolant temperature sensor. 7. Remove covering on lower intake manifold and clean
surface. 8. Place intake manifold gasket on lower manifold. Put upper manifold into place and
install bolts finger tight. 9. Install the generator bracket to intake manifold bolt and the cylinder head
to intake manifold strut bolts (do not tighten.)
10. Following the tightening sequence, tighten intake manifold bolts to 28 Nm (250 in. lbs.) torque.
11. Tighten generator bracket to intake manifold bolt to 54 Nm (40 ft. lbs.) torque. 12. Tighten the
cylinder head to intake manifold strut bolts to 54 Nm (40 ft. lbs.) torque. 13. Connect ground strap
and MAP sensor electrical connector. 14. Connect vacuum harness to intake plenum. Connect
PCV system hoses. 15. Using a new gasket, connect the EGR tube to the intake manifold plenum.
Tighten screws to 22 Nm (200 in. lbs.) torque. 16. Connect electrical connectors to the TPS and
idle air control motor.
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17. Connect vacuum harness to throttle body. 18. Install the direct ignition system (DIS) coils.
Tighten fasteners to 12 Nm (105 in. lbs.) torque. 19. Install fuel hose quick connector fitting to
chassis tubes. Refer to Fuel Hoses, Clamps and Quick Connect Fittings. Push the fitting onto the
chassis
tube until it clicks into place. Pull on the fitting to ensure complete insertion.
20. Install throttle cable and speed control cable (if equipped). 21. Install air inlet resonator. 22.
Connect negative cable to battery.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain
energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off
position.
23. With the ignition key in ON position, access the DRB scan tool ASD Fuel System Test to
pressurize the fuel system. Check for leaks.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Locations
Fuel Return Line: Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Locations
Fuel Supply Line: Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Locations
Fuel Tank Sending Unit
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications
Idle Air Control Motor Screws 2 Nm
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Idle Speed/Throttle Actuator - Electronic: Description and Operation
IDLE AIR CONTROL MOTOR-PCM OUTPUT
The idle air control motor is mounted on the throttle body. The PCM operates the idle air control
motor. The PCM adjusts engine idle speed through the idle air control motor to compensate for
engine load or ambient conditions.
The throttle body has an air bypass passage that provides air for the engine at idle (the throttle
blade is closed). The idle air control motor pintle protrudes into the air bypass passage and
regulates air flow through it.
The PCM adjusts engine idle speed by moving the idle air control motor pintle in and out of the
bypass passage. The adjustments are based on inputs the PCM receives. The inputs are from the
throttle position sensor, crankshaft position sensor, coolant temperature sensor, and various switch
operations (brake, park/neutral, air conditioning). Deceleration die out is also prevented by
increasing airflow when the throttle is closed quickly after a driving (speed) condition.
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Idle Speed/Throttle Actuator - Electronic: Service and Repair
When servicing throttle body components, always reassemble components with new O-rings and
seals where applicable. Never use lubricants on O-rings or seals, damage may result. If assembly
of component is difficult, use water to aid assembly. Use care when removing hoses to prevent
damage to hose or hose nipple.
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from idle air control
motor.
Servicing Idle Air Control Motor
3. Remove idle air control motor mounting screws. 4. Remove motor from throttle body. Ensure the
O-ring is removed with the motor.
INSTALLATION
1. The new idle air control motor has a new O-ring installed on it. If pintle measures more than 1
inch (25 mm) it must be retracted. Use the DRB
Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected.)
2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten
screws to 2 Nm (17 in. lbs.) torque. 4. Connect electrical connector to idle air control motor. 5.
Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3155
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Instructions > Page 3159
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3160
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3162
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3163
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Instructions > Page 3164
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3165
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3166
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3167
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3168
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Instructions > Page 3169
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3170
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3171
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3172
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3173
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3174
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3175
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3176
Automatic Shut Down (ASD) Relay: Connector Views
Power Distribution Center
Automatic Shut Down Relay
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Automatic Shut Down (ASD) Relay: Description and Operation
Power Distribution Center
DESCRIPTION
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and
fuses in the PDC.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02
Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM
monitors the crankshaft position sensor and camshaft position sensor signals to determine engine
speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor
and camshaft position sensor signals when the ignition switch is in the Run position, it will
de-energize the ASD relay.
AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT
OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt
signal at this input indicates to the PCM that the ASD has been activated. This input is used only to
sense that the ASD relay is energized.
When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC).
AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT
The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic
ignition coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and
contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss
bar in the PDC and the relay. The fuse is located in the PDC.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2
Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the
On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position
sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not
receive the crankshaft position sensor and camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the ASD relay.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3178
Power Distribution Center
The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies
the relays and fuses in the PDC.
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown
(ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown
(ASD) Relay > Page 3181
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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Automatic Shut Down (ASD) Relay: Service and Repair
The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover
has a label showing relay and fuse location.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Battery Negative Cable
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3187
Power Distribution Center -- Sheet 8w-10-2
The fuel pump relay is located in the PDC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3188
Fuel Pump Relay: Diagrams
Power Distribution Center
Fuel Pump Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3189
Fuel Pump Relay: Description and Operation
FUEL PUMP RELAY-PCM OUTPUT
The fuel pump relay supplies battery voltage to the fuel pump. The fuel pump relay power circuit
contains a 9 amp fuse. The fuse is located in the PDC.
The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the
relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position.
When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft
position sensor does not detect engine rotation, the PCM de-energizes the relay after
approximately one second.
The fuel pump relay is located in the PDC. A label affixed to the underside of the PDC cover
identifies the relays and fuses in the PDC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3190
Fuel Pump Relay: Testing and Inspection
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3191
terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations
Automatic Shut Down (ASD) Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 3195
Power Distribution Center -- Sheet 8w-10-2
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Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3198
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3199
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3200
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3201
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Information > Diagrams > Diagram Information and Instructions > Page 3202
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Information > Diagrams > Diagram Information and Instructions > Page 3203
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Information > Diagrams > Diagram Information and Instructions > Page 3204
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Information > Diagrams > Diagram Information and Instructions > Page 3205
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Information > Diagrams > Diagram Information and Instructions > Page 3206
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3207
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Information > Diagrams > Diagram Information and Instructions > Page 3208
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Information > Diagrams > Diagram Information and Instructions > Page 3209
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Information > Diagrams > Diagram Information and Instructions > Page 3210
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3211
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3212
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3213
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3214
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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Information > Diagrams > Diagram Information and Instructions > Page 3215
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3216
Automatic Shut Down (ASD) Relay: Connector Views
Power Distribution Center
Automatic Shut Down Relay
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Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Page 3217
Automatic Shut Down (ASD) Relay: Description and Operation
Power Distribution Center
DESCRIPTION
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well. A label on the underside of the PDC cover identifies the relays and
fuses in the PDC.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the 02
Heater Monitor test is being run. when the ignition switch is in the On or Crank position, the PCM
monitors the crankshaft position sensor and camshaft position sensor signals to determine engine
speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor
and camshaft position sensor signals when the ignition switch is in the Run position, it will
de-energize the ASD relay.
AUTOMATIC SHUTDOWN (ASD) SENSE-PCM INPUT
OPERATION The ASD sense circuit informs the PCM when the ASD relay energizes. A 12 volt
signal at this input indicates to the PCM that the ASD has been activated. This input is used only to
sense that the ASD relay is energized.
When energized, the ASD relay supplies battery voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble Code (DTC).
AUTOMATIC SHUTDOWN RELAY-PCM OUTPUT
The Automatic Shutdown (ASD) relay supplies battery voltage to the fuel injectors, electronic
ignition coil and the heating elements in the oxygen sensors.
A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and
contact side of the relay. The ASD relay power circuit contains a 25 amp fuse between the buss
bar in the PDC and the relay. The fuse is located in the PDC.
The PCM controls the relay by switching the ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the ignition switch is in the Off position unless the O2
Heater Monitor test is being run. Refer to On-Board Diagnostics. When the ignition switch is in the
On or Crank position, the PCM monitors the crankshaft position sensor and camshaft position
sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not
receive the crankshaft position sensor and camshaft position sensor signals when the ignition
switch is in the Run position, it will de-energize the ASD relay.
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Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Page 3218
Power Distribution Center
The ASD relay is located in the PDC. A label affixed to the underside of the PDC cover identifies
the relays and fuses in the PDC.
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Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
ASD And Fuel Pump Relay Terminals
ASD And Fuel Pump Relay Terminals
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered.
OPERATION Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays,
terminal 30 is connected to battery voltage at all times.
- The PCM grounds the coil side of the relay through terminal number 85.
- Terminal number 86 supplies voltage to the coil side of the relay.
- When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to
terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the
circuit. Terminal 87A is the center terminal on the relay.
- When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage to the rest of the circuit.
TESTING The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from
connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check
the resistance between terminals 85 and 86. The resistance should be between
75 ± 5 ohms.
3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The
ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge
or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS
TEST.
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Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 3221
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The
ohmmeter should now show continuity between relay
terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and
30.
8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance
tests. If the relay passed the tests, it operates properly. Check the remainder of the
ASD and fuel pump relay circuits.
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Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Testing and Inspection > Page 3222
Automatic Shut Down (ASD) Relay: Service and Repair
The Automatic Shutdown relay (ASD) relay is located in the PDC. The inside top of the PDC cover
has a label showing relay and fuse location.
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank >
Component Information > Description and Operation
Rollover Valve: Description and Operation
DESCRIPTION
All vehicles have rollover valve(s) on top of the fuel tank.
OPERATION
The valves prevent fuel flow through the fuel tank vent valve hoses should the vehicle rollover.
The rollover valves on the fuel tank are not serviceable.
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Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications
Throttle Position Sensor: Specifications
Throttle Position Sensor Screw 2 Nm
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Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3230
Throttle Position Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3231
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3232
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
THROTTLE POSITION SENSOR (TPS)-PCM INPUT
The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a
variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade
position. As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from
approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with
inputs from other sensors, the PCM uses the TPS input to determine current engine operating
conditions and adjust fuel injector pulse width and ignition timing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3233
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to
the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The
center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply
and the remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS
output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output
voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase
as the throttle plate moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3234
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws.
Servicing Throttle Position Sensor
4. Lift throttle position sensor off throttle shaft.
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications
Throttle Body: Specifications
Throttle Body Mounting Nuts 25 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 3238
Throttle Body: Service Precautions
WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR
BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES
OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING CLEANER
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 3239
Throttle Body: Description and Operation
Throttle Body - 2.4L
Throttle Body - 3.0L
Throttle Body - 3.3/3.8L
SYSTEM OPERATION
On all engine assemblies the throttle body's are located on the left side of the intake manifold
plenum. The throttle body houses the throttle position sensor and the idle air control motor. Air flow
through the throttle body is controlled by a cable operated throttle blade located in the base of the
throttle body.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 3240
Throttle Body: Testing and Inspection
1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2.
Ensure that all accessories are off. 3. Shut off engine.
PCV Valve
4. Disconnect the PCV valve hose from the intake manifold nipple. 5. Cap the PCV valve nipple. 6.
Air Metering Fitting 6457
a. Install Air Metering Fitting 6457 (0.125 in. orifice) to the intake manifold PCV nipple. b.
Disconnect the idle purge line from the throttle body nipple.
7.
a. Cap the 3116 inch nipple. b. Connect the DRB scan tool to the data link connector.
8. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one
180°F cycle. 9. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen.
10. The following will then occur:
- Idle air control motor will fully close.
- Idle spark advance will become fixed.
- DRB scan tool displays engine rpm.
11. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum
air-flow is set correctly.
IDLE SPECIFICATION Odometer Reading = Idle RPM Below 1000 Miles = 525-875 RPM Above
1000 Miles = 575-875 RPM
12. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows:
a. Remove the throttle body from engine.
WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OR
BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES
OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING
CLEANER.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 3241
b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle body.
c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and
manifold side of the throttle blade. The edges of the
throttle blade and portions of the throttle bore that are closest to the throttle blade when closed,
must be free of deposits.
d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f.
Install throttle body on manifold.
g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is
not caused by the throttle body.
13. Shut off engine. 14. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple.
Reinstall the PCV valve hose. 15. Uncap the throttle body idle purge nipple and connect the idle
purge line. 16. Remove DRB scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 3242
Throttle Body: Service and Repair
REMOVAL
1. Disconnect negative cable from battery cable. 2. Remove air inlet to throttle body hose clamp.
Air Inlet Resonator
3. Remove 2 screws and air inlet resonator.
Throttle Cable Attachment To Throttle Body Attachment
4. Remove throttle and the speed control (if equipped) cables from lever and bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 3243
Throttle Body Electrical And Vacuum Connections
5. Disconnect electrical connectors from the idle air control motor and throttle position sensor
(TPS). 6. Disconnect vacuum hoses from throttle body. 7. Remove throttle body to intake manifold
attaching nuts. 8. Remove throttle body and gasket.
INSTALLATION
1. Reverse procedure for installation. Tighten throttle body mounting nuts to 25 Nm (225 in. lbs.)
torque.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Service and Repair
Throttle Cable/Linkage: Service and Repair
CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not
damage or kink the core wire inside the cable sheathing.
REMOVAL
1. Working from the engine compartment, hold the throttle body throttle lever in the wide open
position.
Throttle Cable Attachment To Throttle Body Attachment
2. Remove the throttle cable from the throttle body cam.
Accelerator Pedal And Throttle Cable-Front View
3. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from
the upper end of the pedal shaft.
Accelerator Pedal And Throttle Cable-Rear View
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Service and Repair > Page 3247
4. Remove retainer clip from throttle cable and grommet at dash panel. 5. From the engine
compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in
the dash panel. 6. Remove the throttle cable from throttle bracket by carefully compressing both
retaining ears simultaneously. Then gently pull the throttle cable
from throttle bracket.
INSTALLATION
1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2.
Install the cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From
inside the vehicle, hold up the pedal and install throttle cable and cable retainer in the upper end of
the pedal shaft. 4. At the dash panel, install the cable retainer clip between the end of the throttle
cable fitting and grommet. 5. From the engine compartment, rotate the throttle lever wide open and
install the throttle cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Specifications
Throttle Position Sensor: Specifications
Throttle Position Sensor Screw 2 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Specifications > Page 3251
Throttle Position Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Specifications > Page 3252
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Specifications > Page 3253
Throttle Position Sensor: Description and Operation
Throttle Position Sensor
THROTTLE POSITION SENSOR (TPS)-PCM INPUT
The TPS is mounted on the throttle body and connected to the throttle blade shaft. The TPS is a
variable resistor that provides the (PCM) with an input signal (voltage) representing throttle blade
position. As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The TPS output voltage to the PCM varies from
approximately 0.5 volt at minimum throttle opening (idle) to 4 volts at wide open throttle. Along with
inputs from other sensors, the PCM uses the TPS input to determine current engine operating
conditions and adjust fuel injector pulse width and ignition timing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Specifications > Page 3254
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry, refer to the DRB scan tool and
appropriate Powertrain Diagnostics Procedures. To test the throttle position sensor only, refer to
the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The
center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply
and the remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS
output voltage should be approximately 0.38 volts to 1.2 volts. At wide open throttle, TPS output
voltage should be approximately 3.1 volts to 4.4 volts. The output voltage should gradually increase
as the throttle plate moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Specifications > Page 3255
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws.
Servicing Throttle Position Sensor
4. Lift throttle position sensor off throttle shaft.
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in. lbs.) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Component Information > Locations
Firing Order
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor ...................................................................................................................
................................................... 14 Nm (125 in. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 3267
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 3268
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 3269
Camshaft Position Sensor: Description and Operation
Camshaft Position Sensor Location
DESCRIPTION
The camshaft position sensor is mounted in the front of the timing case cover.
Camshaft Position Sensor
Camshaft Sprocket
OPERATION
The camshaft position sensor provides cylinder identification to the Powertrain Control Module
(PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass
underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the
pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each
group of camshaft pulses.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 3270
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Ignition Coil Pack
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder
the flat spot and notches identify, they do not indicate TDC position.
CAMSHAFT POSITION SENSOR-PCM INPUT
The PCM determines fuel injection synchronization and cylinder identification from inputs provided
by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM
determines crankshaft position.
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it.
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft
pulses.
The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of
the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel
Injection-Service Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 3271
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 3272
Camshaft Position Sensor: Service and Repair
REMOVAL
Camshaft Position Sensor
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector.
Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt.
Camshaft Sensor Removal/Installation
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 3273
3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the
sensor lead. There is an O-ring on the sensor case. The O-ring may make removal
difficult. A light tap to top of sensor prior to removal may reduce force needed for removal.
INSTALLATION
Camshaft Position Sensor And Spacer
If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If
the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is
positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring
prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor
down until contact is made with the camshaft gear. While holding the sensor in this position, install
and tighten the retaining bolt 14
Nm (125 in. lbs.) torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 3277
Crankshaft Position Sensor Location
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 3278
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 3279
Crankshaft Position Sensor: Description and Operation
DESCRIPTION
Crankshaft Position Sensor Location
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing. The bottom of the sensor is positioned next to the drive plate.
OPERATION
Crankshaft Position Sensor
Timing Slots
The crankshaft position sensor detects slots cut into the transmission driveplate extension. There
are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the
position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last
slot,
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 3280
it determines crankshaft position (which piston will next be at TDC) from the camshaft position
sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°,
and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
CRANKSHAFT POSITION SENSOR-PCM INPUT
The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3
sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of
the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position
(which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM
one engine revolution to determine crankshaft position.
The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing
and presence of misfire. Once crankshaft position has been determined, the PCM begins
energizing the injectors in sequence.
The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor.
The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of
sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft
position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 3281
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 3282
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Raise and support vehicle.
Crankshaft Position Sensor Connector
2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3.
Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out
of the trans axle housing.
INSTALLATION
Crankshaft Position Sensor And Spacer
NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the face of the new sensor.
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications
Ignition Cable: Specifications
Cable = Maximum Resistance
#1 = 18.5 K Ohms
#2 = 15.5 K Ohms
#3 = 20.4 K Ohms
#4 = 21.2 K Ohms
#5 = 27.7 K Ohms
#6 = 26.7 K Ohms
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications > Page 3286
Ignition Cable: Description and Operation
DESCRIPTION
The spark plug cables and spark plug boots are made from high temperature silicon materials. The
spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The
heat shields slide over the spark plug boots. The notches on the heat shields ensure the spark plug
boot and shield twist together during spark plug boot removal. They also identify proper heat shield
installation on the boot for service. Refer to Spark Plug Cable Replacement. All spark plug cable
leads are properly identified with cylinder numbers. The inside of the spark plug boot is coated with
a special high temperature silicone grease for greater sealing and to minimize boot bonding to the
spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature
plastic material. Under normal driving conditions, the spark plug cables have a recommended
service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles
for severe driving conditions per schedule B.
The spark plug heat shield can be reused if an ignition cable is replaced due to failure. Never reuse
heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing.
Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. The
bottom of the spark plug heat shield must make contact with the spark plug hex.
The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not
touch the coil mounting bolt to avoid abrasion/dielectric failures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications > Page 3287
Ignition Cable: Service and Repair
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the ignition cables.
Spark Plug Boot/Heat Shield Orientation
The spark plug boot heat shield needs to be installed correctly on the boot before being installed on
the engine. If it is not installed correctly engine misfire would occur.
Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly.
Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely
important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield
must make contact with the spark plug socket hex.
CAUTION: Never coat the inside of spark plug boots with silicone grease. Some types of silicone
grease can damage the ignition cable conductor.
Spark Plug Cables # 3 And # 5
REMOVAL
1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the
spark plug. Twist the boot slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle.
This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug
insulator clean with a dry cloth before installation.
3. Remove the cable from the retaining bracket. Make sure that they are also detached from the
rear retaining clip mounted on the rear of the intake
manifold.
INSTALLATION
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated. A click sound should be heard
or terminal engagement is felt when the terminals are properly attached.
2. Install the cable into the retaining bracket. Make sure that they are also attached to the rear
retaining clip mounted on the rear of the intake
manifold.
3. Install the resonator.
Spark Plug Cable # 1
REMOVAL
1. Remove the accessory drive belt. 2. Remove the four bolts from the upper half of the generator
bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as
possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull
straight back. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle.
This could damage the spark plug insulator, terminal, or the cable insulation. Wipe spark plug
insulator clean with a dry cloth before installation.
5. Remove the cable from the retaining bracket.
INSTALLATION
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated. A click sound should be heard
or terminal engagement is felt when the terminals are properly attached.
2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install
the accessory drive belt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise
Ignition Coil: Customer Interest Radio - Poor AM Reception/Ignition Noise
NUMBER: 08-45-99
GROUP: Electrical
DATE: Dec. 31, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2,
1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO.
81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
SUBJECT: AM Radio Reception
OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module,
adding a jumper harness, ground strap and tie-strap.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition
noise (static that varies with engine RPM) on low power/distant stations.
DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that
varies with engine RPM is heard check the antenna connection, the antenna ground, the ground
straps across the right side motor mount, and from the back of the engine to the dash panel. If
these check ok but the static condition still exists, perform the Repair Procedure.
PARTS REQUIRED:
1 05016107AA Shield Package
Contents Of Shield Package:
1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts
1 05016105AA Wiring Repair Package 1996-1998
1 05016106AA Wiring Repair Package 1999-2000
Contents of Wiring Packages:
1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor,
1-Capacitor Mounting Bolt
REPAIR PROCEDURE:
1. Disconnect the negative battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 3296
Fig. 1
2. Disconnect the electrical connector from the ignition coil module, Figure 1.
3. Remove the ignition coil module bottom-forward mounting bolt and discard.
Fig. 2
4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque
the screw to 10-15 Nm (85-125 in. lbs.)
5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then
connect the jumper harness between the ignition coil module and the powertrain harness
connector, Figure 2.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 3297
Fig. 3
Fig. 3A
6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of
the powertrain harness (see fig. 3 or fig. 3a).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 3298
Fig. 4
7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4.
8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs.
Torque studs to 10-15 Nm (85-125 in. lbs.)
Fig. 5
9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure
5. Torque the nuts to 10-15 Nm (85-125 in. lbs.).
10. Turn the ignition switch to the Unlock position so the steering wheel can rotate.
11. Raise vehicle. Then turn the front wheels to the left.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 3299
Fig. 6
12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut
assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap
eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching
bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse
panel/frame to 11 Nm (95 in. lbs.), Figure 6.
13. Center the front wheels and lower the vehicle.
14. Connect the negative battery cable and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-12-02-91 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise
Ignition Coil: All Technical Service Bulletins Radio - Poor AM Reception/Ignition Noise
NUMBER: 08-45-99
GROUP: Electrical
DATE: Dec. 31, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2,
1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO.
81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
SUBJECT: AM Radio Reception
OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module,
adding a jumper harness, ground strap and tie-strap.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition
noise (static that varies with engine RPM) on low power/distant stations.
DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that
varies with engine RPM is heard check the antenna connection, the antenna ground, the ground
straps across the right side motor mount, and from the back of the engine to the dash panel. If
these check ok but the static condition still exists, perform the Repair Procedure.
PARTS REQUIRED:
1 05016107AA Shield Package
Contents Of Shield Package:
1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts
1 05016105AA Wiring Repair Package 1996-1998
1 05016106AA Wiring Repair Package 1999-2000
Contents of Wiring Packages:
1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor,
1-Capacitor Mounting Bolt
REPAIR PROCEDURE:
1. Disconnect the negative battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 3305
Fig. 1
2. Disconnect the electrical connector from the ignition coil module, Figure 1.
3. Remove the ignition coil module bottom-forward mounting bolt and discard.
Fig. 2
4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque
the screw to 10-15 Nm (85-125 in. lbs.)
5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then
connect the jumper harness between the ignition coil module and the powertrain harness
connector, Figure 2.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 3306
Fig. 3
Fig. 3A
6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of
the powertrain harness (see fig. 3 or fig. 3a).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 3307
Fig. 4
7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4.
8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs.
Torque studs to 10-15 Nm (85-125 in. lbs.)
Fig. 5
9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure
5. Torque the nuts to 10-15 Nm (85-125 in. lbs.).
10. Turn the ignition switch to the Unlock position so the steering wheel can rotate.
11. Raise vehicle. Then turn the front wheels to the left.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 3308
Fig. 6
12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut
assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap
eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching
bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse
panel/frame to 11 Nm (95 in. lbs.), Figure 6.
13. Center the front wheels and lower the vehicle.
14. Connect the negative battery cable and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-12-02-91 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Electrical Specifications
Ignition Coil: Electrical Specifications
Coil Manufacturer = Diamond Electric (Brass Towers) Primary Resistance at 21° C - 27° C (70° F 80° F) = 0.45 to 0.65 ohms
Secondary Resistance at 21° C - 27° C (70° F - 80° F) = 7,000 to 15,800 ohms
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Electrical Specifications > Page 3311
Ignition Coil: Mechanical Specifications
Ignition Coil Fasteners 12 Nm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 3312
Ignition Coil: Locations
Ignition Coil
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 3313
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 3314
Knock Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 3315
Ignition Coil: Description and Operation
WARNING: THE DIRECT IGNITION SYSTEM GENERATES APPROXIMATELY 40,000 VOLTS.
PERSONAL INJURY COULD RESULT FROM CONTACT WITH THIS SYSTEM.
Ignition Coil Pack
DESCRIPTION
The ignition coil assembly consists of 3 independent coils molded together. The coil assembly is
mounted on the intake manifold. Spark plug cables route to each cylinder from the coil.
OPERATION
The coil fires two spark plugs every power stroke. One plug is the cylinder under compression, the
other cylinder fires on the exhaust stroke. The Powertrain Control Module (PCM) determines which
of the coils to charge and fire at the correct time.
Coil 1 fires cylinders 1 and 4, coil 2 fires cylinders 2 and 5, coil 3 fires cylinders 3 and 6.
The Auto Shutdown (ASD) relay provides battery voltage to the ignition coil. The PCM provides a
ground contact (circuit) for energizing the coil. When the PCM breaks the contact, the energy in the
coil primary transfers to the secondary causing the spark. The PCM will de-energize the ASD relay
if it does not receive the crankshaft position sensor and camshaft position sensor inputs. Refer to
Auto Shutdown (ASD) Relay-PCM Output, for relay operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing
and Inspection > Ignition Coil Test
Ignition Coil: Testing and Inspection Ignition Coil Test
Coil 1 fires cylinders 1 and 4, coil 2 fires cylinders 2 and 5, and coil 3 fires cylinders 3 and 6. Each
coil tower is labeled with the number of the corresponding cylinder.
Ignition Coil Electrical Connector
1. Disconnect the electrical connector from the coil pack. 2. Measure the primary resistance of
each coil. At the coil, connect an ohmmeter between the B+ pin and the pin corresponding to the
cylinders in
question. Resistance on the primary side of each coil should be 0.53 - 0.65 ohm at 21° to 27° C
(70° to 80° F). A coil that has not been allowed to cool off, would result in inaccurate measurement
results. Replace the coil if resistance is not within tolerance.
Checking Ignition Coil Secondary Resistance
3. Remove ignition cables from the secondary towers of the coil. Measure the secondary resistance
of the coil between the towers of each individual
coil. Secondary resistance should be 10,900 to 14,700 ohms. Replace the coil if resistance is not
within tolerance.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing
and Inspection > Ignition Coil Test > Page 3318
Ignition Coil: Testing and Inspection Testing For Spark at Coil
WARNING: THE DIRECT IGNITION SYSTEMS GENERATES APPROXIMATELY 40,000 VOLTS.
PERSONAL INJURY COULD RESULT FROM CONTACT WITH THIS SYSTEM.
The coil pack contains independent coils. Each coil must be checked individually.
CAUTION: Spark plug wire damage may occur if the spark plug is moved more than 1/4 inch away
from the engine ground.
CAUTION: Do not leave any one spark plug cable disconnected any longer than 30 seconds or
possible heat damage to catalytic converter will occur.
CAUTION: Test must be performed at idle and in park only with the parking brake on.
Use a new spark plug and spark plug cable for the following test.
Testing For Spark
1. Insert a new spark plug into the new spark plug boot. Ground the plug to the engine. Do not hold
with your hand. 2. Starting with coil insulator #1, remove it from the DIS coil. 3. Plug the test spark
plug cable onto #1 coil tower. Make sure a good connection is made; there should be a click sound.
4. Crank the engine and look for spark across the electrodes of the spark plug.
CAUTION: Always install the cable back on the coil tower after testing to avoid damage to the coil
and catalytic converter.
5. Repeat the above test for the remaining coils. If there is no spark during all cylinder tests,
proceed to the Failure To Start Test. 6. If one or more tests indicate irregular, weak, or no spark,
proceed to check coil test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Testing
and Inspection > Page 3319
Ignition Coil: Service and Repair
REMOVAL
Ignition Coil Removal
1. Remove spark plug cables from coil. Always twist the spark plug boots to break the seal with the
plug and pull straight back on the boot. 2. Remove ignition coil electrical connector. 3. Remove
ignition coil mounting screws. 4. Remove ignition coil.
INSTALLATION
1. Reverse the above procedure for installation. Tighten mounting screws to 12 Nm (105 in. lbs.)
torque. 2. Transfer spark plug cables to new coil pack. The coil pack towers and cables are
numbered with the cylinder identification.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3323
Knock Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3324
Knock Sensor: Description and Operation
Knock Sensor
KNOCK SENSOR-PCM INPUT
The knock sensor is only on these engines.
The knock sensor threads into the side of the cylinder block in front of the starter. When the knock
sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response,
the PCM retards ignition timing for all cylinders by a scheduled amount.
Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM.
As the intensity of the engine knock vibration increases, the knock sensor output voltage also
increases.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3325
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: ignition timing,
cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude
increases with the increase of engine knock. The knock sensor can be tested with a digital
voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to
approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 3326
Knock Sensor: Service and Repair
Knock Sensor
The knock sensor threads into the side of the cylinder block in front of the starter.
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening
effects knock sensor performance, possibly
causing improper spark control.
2. Attach electrical connector to knock sensor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor ...................................................................................................................
................................................... 14 Nm (125 in. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 3331
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 3332
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 3333
Camshaft Position Sensor: Description and Operation
Camshaft Position Sensor Location
DESCRIPTION
The camshaft position sensor is mounted in the front of the timing case cover.
Camshaft Position Sensor
Camshaft Sprocket
OPERATION
The camshaft position sensor provides cylinder identification to the Powertrain Control Module
(PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass
underneath it. The PCM keeps track of crankshaft rotation and identifies each cylinder by the
pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each
group of camshaft pulses.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 3334
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Ignition Coil Pack
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs represent which cylinder
the flat spot and notches identify, they do not indicate TDC position.
CAMSHAFT POSITION SENSOR-PCM INPUT
The PCM determines fuel injection synchronization and cylinder identification from inputs provided
by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM
determines crankshaft position.
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it.
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft
pulses.
The distance between the bottom of sensor and the camshaft sprocket is critical to the operation of
the system. When servicing the camshaft position sensor, refer to the Multi-Port Fuel
Injection-Service Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 3335
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 3336
Camshaft Position Sensor: Service and Repair
REMOVAL
Camshaft Position Sensor
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector.
Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor. There is a hole in the bracket for tool access to the sensor bolt.
Camshaft Sensor Removal/Installation
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 3337
3. Rotate sensor away from block. 4. Pull sensor up out of the chain case cover. Do not pull on the
sensor lead. There is an O-ring on the sensor case. The O-ring may make removal
difficult. A light tap to top of sensor prior to removal may reduce force needed for removal.
INSTALLATION
Camshaft Position Sensor And Spacer
If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If
the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is
positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring
prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor
down until contact is made with the camshaft gear. While holding the sensor in this position, install
and tighten the retaining bolt 14
Nm (125 in. lbs.) torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 3341
Crankshaft Position Sensor Location
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 3342
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 3343
Crankshaft Position Sensor: Description and Operation
DESCRIPTION
Crankshaft Position Sensor Location
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing. The bottom of the sensor is positioned next to the drive plate.
OPERATION
Crankshaft Position Sensor
Timing Slots
The crankshaft position sensor detects slots cut into the transmission driveplate extension. There
are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the
position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last
slot,
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 3344
it determines crankshaft position (which piston will next be at TDC) from the camshaft position
sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°,
and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
CRANKSHAFT POSITION SENSOR-PCM INPUT
The crankshaft position sensor senses slots cut into the transaxle driveplate extension. There are 3
sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of
the last slot in each group. Once the PCM senses the last slot, it determines crankshaft position
(which piston will next be at TDC) from the camshaft position sensor input. It may take the PCM
one engine revolution to determine crankshaft position.
The PCM uses the crankshaft position sensor signal to determine injector sequence, ignition timing
and presence of misfire. Once crankshaft position has been determined, the PCM begins
energizing the injectors in sequence.
The crankshaft position sensor is located in the transaxle housing, above the vehicle speed sensor.
The bottom of the sensor is positioned next to the drive plate. The distance between the bottom of
sensor and the drive plate is critical to the operation of the system. When servicing the crankshaft
position sensor, refer to the appropriate Multi-Port Fuel Injection Service Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 3345
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 3346
Crankshaft Position Sensor: Service and Repair
REMOVAL
1. Raise and support vehicle.
Crankshaft Position Sensor Connector
2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector. 3.
Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out
of the trans axle housing.
INSTALLATION
Crankshaft Position Sensor And Spacer
NOTE: It the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the face of the new sensor.
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in. lbs.) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest:
> 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest:
> 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 3356
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 3362
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Switch Lock Cylinder: > NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect
Headlamp Control Module: All Technical Service Bulletins Recall 99V116000: Headlamp Module
Defect
Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL"
as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment."
These vehicles do not comply with requirements of FMVSS No. 108.
All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters.
Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on
an agreed upon service date and do not receive the free remedy within a reasonable time should
contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3373
Ignition Switch Lock Cylinder: Description and Operation
DESCRIPTION
The lock cylinder is inserted in the end of the housing opposite the ignition switch.
OPERATION
Ignition Lock Cylinder Detents
The ignition key rotates the cylinder to 5 different detents: Accessory
- Off (lock)
- Unlock
- On/Run
- Start
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3374
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3375
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 3379
Knock Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 3380
Knock Sensor: Description and Operation
Knock Sensor
KNOCK SENSOR-PCM INPUT
The knock sensor is only on these engines.
The knock sensor threads into the side of the cylinder block in front of the starter. When the knock
sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response,
the PCM retards ignition timing for all cylinders by a scheduled amount.
Knock sensors contain a piezoelectric material which sends an input voltage (signal) to the PCM.
As the intensity of the engine knock vibration increases, the knock sensor output voltage also
increases.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 3381
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: ignition timing,
cylinder pressure, fuel octane, etc. The knock sensor generates an AC voltage whose amplitude
increases with the increase of engine knock. The knock sensor can be tested with a digital
voltmeter. The RMS voltage starts at about 20mVac (at about 700 rpm) and increases to
approximately 600 mVac (5000 rpm). If the output falls outside of this range a DTC will be set.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 3382
Knock Sensor: Service and Repair
Knock Sensor
The knock sensor threads into the side of the cylinder block in front of the starter.
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to (10 Nm 7 ft. lbs.) torque. Over or under tightening
effects knock sensor performance, possibly
causing improper spark control.
2. Attach electrical connector to knock sensor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications
Spark Plug: Specifications
Electrode Gap ......................................................................................................................................
.................................. 1.21-1.34 mm (0.048-0.053 in) Torque .............................................................
.............................................................................................................................................. 28 Nm
(20 ft lb)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3386
Spark Plug: Application and ID
Spark Plug ...........................................................................................................................................
............................................................... RN14PMP5 Thread .............................................................
................................................................................................................................................ (14mm)
3/4 in.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3387
Spark Plug: Description and Operation
SPARK PLUGS RESISTER
DESCRIPTION All engines use resistor spark plugs. They have resistance values ranging from
6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester.
Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Setting Spark Plug Electrode Gap
Refer to the Specifications for gap and type of spark plug.
SPARK PLUGS PLATINUM
DESCRIPTION The engine utilize platinum spark plugs. Refer to the maintenance schedule.
All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000
ohms when checked with at least a 1000 volt spark plug tester.
Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Platinum Pads
The spark plugs are double platinum and have a recommended service life of 100,000 miles for
normal driving conditions per schedule A. The spark plugs have a recommended service life of
75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both
electrode ends as shown. Extreme care must be used to prevent spark plug cross threading,
mis-gaping and ceramic insulator damage during plug removal and installation.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3388
Spark Plug: Testing and Inspection
Spark Plug Condition
Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken
porcelain insulators. Keep plugs arranged in the order in which they were removed from the
engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended.
Normal Operating Conditions
Normal Operation And Cold (Carbon) Fouling
The few deposits present will be probably light tan or slightly gray in color with most grades of
commercial gasoline. There will not be evidence of electrode burning. Gap growth will not average
more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation for non
platinum spark plugs. Non-platinum spark plugs that have normal wear can usually be cleaned, and
then reinstalled.
CAUTION: Never attempt to tile the electrodes or use a wire brush for cleaning platinum spark
plugs. This would damage the platinum pads which would shorten spark plug life.
Some fuel refiners in several areas of the United States have introduced a manganese additive
(MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark
plug with a rust colored deposit. The rust color deposits can be mis diagnosed as being caused by
coolant in the combustion chamber. Spark plug performance may be affected by MMT deposits.
Cold Fouling (Carbon Fouling) Cold fouling is sometimes referred to as carbon fouling because the
deposits that cause cold fouling are basically carbon. A dry, black deposit on one or two plugs in a
set may be caused by sticking valves or misfire conditions. Cold (carbon) fouling of the entire set
may be caused by a clogged air cleaner.
Cold fouling is normal after short operating periods. The spark plugs do not reach a high enough
operating temperature during short operating periods. Replace carbon fouled plugs with new spark
plugs.
Fuel Fouling A spark plug that is coated with excessive wet fuel is called fuel fouled. This condition
is normally observed during hard start periods. Clean fuel fouled spark plugs with compressed air
and reinstall them in the engine.
Oil Fouling A spark plug that is coated with excessive wet oil is oil fouled. In older engines, wet
fouling can be caused by worn rings or excessive cylinder wear. Break-in fouling of new engines
may occur before normal oil control is achieved. Replace oil fouled spark plugs with new ones.
Oil Or Ash Encrusted
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3389
Oil Or Ash Encrusted
If one or more plugs are oil or ash encrusted, evaluate the engine for the cause of oil entering the
combustion chambers. Sometimes fuel additives can cause ash encrustation on an entire set of
spark plugs. Ash encrusted spark plugs can be cleaned and reused.
High Speed Miss When replacing spark plugs because of a high speed miss condition; wide open
throttle operation should be avoided for approximately 80 km (50 miles) after installation of new
plugs. This will allow deposit shifting in the combustion chamber to take place gradually and avoid
plug destroying splash fouling shortly after the plug change.
Electrode Gap Bridging
Electrode Gap Bridging
Loose deposits in the combustion chamber can cause electrode gap bridging. The deposits
accumulate on the spark plugs during continuous stop-and-go driving. When the engine is
suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between
the electrodes. This short circuits the electrodes. Spark plugs with electrode gap bridging can be
cleaned and reused.
Scavenger Deposits
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Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3390
Scavenger Deposits
Fuel scavenger deposits may be either white or yellow. They may appear to be harmful, but are a
normal condition caused by chemical additives in certain fuels. These additives are designed to
change the chemical nature of deposits and decrease spark plug misfire tendencies. Notice that
accumulation on the ground electrode and shell area may be heavy but the deposits are easily
removed. Spark plugs with scavenger deposits can be considered normal in condition, cleaned and
reused.
Chipped Electrode Insulator
Chipped Electrode Insulator
A chipped electrode insulator usually results from bending the center electrode while adjusting the
spark plug electrode gap. Under certain conditions, severe detonation also can separate the
insulator from the center electrode. Spark plugs with chipped electrode insulators must be
replaced.
Preignition Damage
Preignition Damage
Excessive combustion chamber temperature can cause preignition damage. First, the center
electrode dissolves and the ground electrode dissolves somewhat later. Insulators appear relatively
deposit free. Determine if the spark plugs are the correct type, as specified on the VECI label, or if
other operating conditions are causing engine overheating.
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Specifications > Page 3391
Spark Plug Overheating
Spark Plug Overheating
Overheating is indicated by a white or gray center electrode insulator that also appears blistered.
The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of
operation. This suggests that a plug with a cooler heat range rating should be used. Over
advanced ignition timing, detonation and cooling system malfunctions also can cause spark plug
overheating.
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Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3392
Spark Plug: Service and Repair
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
server injury/burns and can cause damage to the ignition cables.
Spark Plug Boot/Heat Shield Orientation
Use extreme care when removing and installing the spark plug cables. The spark plug boot heat
shield needs to be installed correctly on the boot before being installed on the engine. If it is not
installed correctly engine misfire would occur.
Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly
Spark Plug # 3 AND # 5
REMOVAL
1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen
bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as
close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with
the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug
boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation.
Wipe spark plug insulator]ator clean with a dry cloth before installation.
6. Remove spark plug
INSTALLATION
1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables,
make sure spark plug insulator and terminals are fully seated. A click sound should be heard or felt
when
the terminals are properly attached.
3. Install the cable into the retaining bracket. Make sure that they are also attached to the rear
retaining clip mounted on the rear of the intake
manifold.
4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6.
Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator.
Spark Plug # 1
REMOVAL
1. Remove the accessory drive belt. 2. Remove the 4 bolts from the upper half of the generator
bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as
possible to the spark plug. Twist the boot/shield assembly slightly to break its seal with
the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug
boot at an angle. This could damage the spark plug insulator, terminal, or the insulation. Wipe
spark plug insulator clean with a dry cloth before installation.
5. Remove spark plug
INSTALLATION
1. Install spark plug and tighten to 28 Nm (20 ft. lbs.). 2. When installing the spark plug cables,
make sure the coil or spark plug insulator and terminals are fully seated. A click sound should be
heard or
felt when the terminals are properly attached.
3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the
accessory drive belt.
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
A604 (41TE) 4 Speed Transaxle
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Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications
Control Module: Specifications
Sixty-Way Connector 35 in.lb
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Page 3404
Transmission Control Module
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Diagram Information and Instructions
Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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Diagram Information and Instructions > Page 3407
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Diagram Information and Instructions > Page 3408
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Diagram Information and Instructions > Page 3409
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Diagram Information and Instructions > Page 3410
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Diagram Information and Instructions > Page 3411
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Diagram Information and Instructions > Page 3413
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Diagram Information and Instructions > Page 3414
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diagram Information and Instructions > Page 3416
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Diagram Information and Instructions > Page 3420
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3425
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Page 3426
Control Module: Description and Operation
AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT
The electronic automatic transaxle control module and the PCM supply information to each other
through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the
information when adjusting the fuel and ignition strategy.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Page 3427
Control Module: Service and Repair
OVERVIEW
Do not interchange Transmission Control Modules with previous year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed: Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
REMOVAL
Fig. 27
1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then
disconnect the 60 way connector on Transmission
Control Module.
Fig. 28
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Page 3428
Fig. 29
2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28
and 29).
INSTALLATION
1. To install, reverse removal procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations
Transmission Control System Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 3432
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 3433
Transmission Control System Relay: Diagrams
Power Distribution Center
Transmission Control Relay (EATX)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 3434
Transmission Control System Relay: Description and Operation
TRANSMISSION CONTROL RELAY
The transmission control relay is located in the Power Distribution Center (PDC) on the left side of
the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is
used to supply power to the solenoid pack when the transmission is in normal operating mode.
When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in
mode. After a controller reset (ignition key turned to the run position or after cranking engine), the
TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for
no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack
pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify
that the voltage is greater than 3 volts.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations
Autostick/Overdrive Off
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations >
Page 3440
Autostick/Overdrive Switch Connector Pin Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations
Transmission Mode Switch: Locations
For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Locations > Page 3444
Transmission Mode Switch: Diagrams
For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 3449
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 3450
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Page 3451
Transmission Range Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Page 3452
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Page 3453
Transmission Position Switch/Sensor: Description and Operation
Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical
TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT
The park/neutral switch is located on the transaxle housing.
If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral.
This input is used to determine idle speed (varying with gear selection) and ignition timing advance.
The park neutral switch is sometimes referred to as the neutral safety switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Page 3454
Transmission Position Switch/Sensor: Service and Repair
The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
Fig. 20
3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission
range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8.
Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
Fig. 21
11. Place valve body on workbench (Fig. 21).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Page 3455
Fig. 22
12. Remove TRS retaining screw (Fig. 22).
Fig. 23
13. Remove manual shaft seal (Fig. 23).
Fig. 24
14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24).
INSTALLATION
1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.)
Reseal transaxle oil pan using RTV.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 3464
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control > Page 3470
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Page 3471
Transmission Speed Sensor: Specifications
Speed Sensor Input 20 ft.lb
Output 20 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Page 3472
Input Speed Sensor/Output Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Input Speed Sensor
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Input Speed Sensor > Page 3475
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Input Sensor
Transmission Speed Sensor: Service and Repair Input Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 25
The input speed sensor is located to the left of the manual shift lever (Fig. 25).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Input Sensor > Page 3478
Transmission Speed Sensor: Service and Repair Output Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 26
The output speed sensor is located to the right of the manual shift lever (Fig. 26).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 24-10-99A > Aug > 99 > PCM - A/C System Blows Warm
Air Intermittently.
PROM - Programmable Read Only Memory: Customer Interest PCM - A/C System Blows Warm Air
Intermittently.
NUMBER: 24-10-99 Rev. A
GROUP: Heating And A/C
DATE: Aug. 20, 1999
THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 24-10-99 DATED MAY 28,
1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND EXCLUDES CERTAIN ENGINE APPLICATIONS.
SUBJECT: A/C System Blows Warm Air Intermittently
OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control
Module (PCM) with new software (calibration changes).
MODELS:
1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market)
**NOTE:
THIS INFORMATION APPLIES TO ALL APPLICATIONS EXCEPT NS MODELS WITH A 3.0L
ENGINE AND GS MODELS WITH A 2.4L/4 SPEED EATX COMBINATION.**
SYMPTOM/CONDITION:
Some vehicles may exhibit an intermittent condition where the A/C system blows warm air after the
A/C system had been working properly. This could occur when the vehicle is travelling above 40
mph and the engine is NOT in an overheat condition. The discharge vents may suddenly blow
warm air continuously until the A/C select button is re-selected or the vehicle is re-started. Once
the A/C select button is re-selected or vehicle is re-started, the A/C system will function normally
again.
DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB
III(R) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems
are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the
repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are
present and the customer has described the above symptoms, perform the Repair Procedure.
NOTE:
WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE
LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED
CONTROLLERS AS NECESSARY.
PARTS REQUIRED:
1 04669020 Label, Authorized Software Update
1 04275086 Label, Authorized Modification
EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7OOO/7001 J1962 Cable
1 MDS2
NOTE:
THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE
MDS2 SYSTEM MUST BE OPERATING AT CIS CD2034 OR HIGHER.
REPAIR PROCEDURE:
1. Log onto the MDS2 system.
2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and
switch the ignition key to "ON"
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Air Intermittently. > Page 3487
3. Using the arrow keys, select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN
MENU SCREEN.
4. Using the arrow keys, select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU
SCREEN.
NOTE:
ONCE MDS2, DRB III(R) AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE
CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY
THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2
SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO
BEGIN SESSION.
5. Push the FLASH tab on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
7. Select the new software part number with the light pen and click UPDATE CONTROLLER
SOFTWARE.
8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
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Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 24-10-99A > Aug > 99 > PCM - A/C System Blows Warm
Air Intermittently. > Page 3488
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-44-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB
Readiness Monitor Information
Technical Service Bulletin # 25-02-98 Date: 981023
I/M Testing - OBDII CARB Readiness Monitor Information
NO: 25-02-98
GROUP: Emissions
DATE: Oct. 23, 1998
SUBJECT:
I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information
MODELS:
1996 - 1999 (AB) Ram Van/Wagon
1996 - 1999 (AN) Dakota
1996 - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
1996 - 1999 (FJ) Avenger/Sebring/Talon
1996 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1995 - 1999 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper Roadster/Coupe
1997 - 1999 (TJ) Wrangler
1999 (WJ) Grand Cherokee
1996 - 1999 (XJ) Cherokee
1996 - 1998 (ZJ) Grand Cherokee
NOTE:
THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE
ENGINES.
DISCUSSION:
Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a
prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their
self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or
more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their
tests.
It is important to understand that the MIL will not be illuminated because OBD Readiness reads
"NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions
system occurs. It is possible to have MIL illumination for a detected failure while at the same time
having a "NO" for an OBO Readiness monitor.
NOTE:
MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER
DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS
BULLETIN.
OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM
replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items
occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for
OBD Readiness.
Some customers may be directed back to their dealers for assistance when an I/M test station has
not allowed an I/M test due to Readiness status. The following procedures will help technicians
efficiently run the Readiness tests so an owner can have their I/M test completed.
EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH7000/7001 J1962Cable
1 CH7OlO J1962 MMC Cable
POLICY: Reimbursable within the provisions of the warranty.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB
Readiness Monitor Information > Page 3493
TIME ALLOWANCE:
Labor Operation No: 25-01-01-91 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
This bulletin involves operating the vehicle under specific parameters to run or complete the OBD
monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions
application. In addition, the parameters to run each monitor will vary.
Preliminary Checks
1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate
as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit.
2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year
diagnostics, engine, DTC's and related functions, read DTC's.
3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the
engine running.
NOTE:
EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS
FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE
ATTEMPTING TO RUN THE MONITORS.
OBD "CARB" Readiness Check
1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status.
2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO"
tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned
to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read
"YES".
NOTE:
THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES
APPLICABLE FOR THE VEHICLE BEING WORKED ON.
The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to
run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The
pre-test/monitor test screen lists all the preliminary parameters that must be met along with the
running parameters for that specific monitor to run. An example of one screen is shown in Figure 1.
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Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB
Readiness Monitor Information > Page 3494
NOTE:
1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN.
PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE
MONITORS RUN WILL BE SIMILAR.
The following explains how to interpret each section of the screen:
PRE-TEST REQUIREMENTS
The pre-test requirements include all the operating parameters that must be met before the actual
test can run. The vehicle must be operated until each item within the pre-test section are fulfilled.
LOW VALUE/HIGH VALUE/BAR GRAPH
The low value/high value provides the minimum and maximum operating conditions for each item
(ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when
the lowest value required for each item is met. This provides a visual indication that the parameters
are being met. The vehicle should be driven until most of each pre-test bar graph is filled.
MONITOR REQUIREMENTS
Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in
the monitor requirements section for the monitors to begin running. As the monitor begins to run,
the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle
operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician
must determine if the pre-test requirements or the monitor requirements have fallen outside the
window for the test and the vehicle must be driven accordingly for the test to restart. When the
monitor completes its test, the DRB III(R) will beep 3 consecutive times.
NOTE:
THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE
PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR
SCREEN FOR THIS MONITOR.
MONITOR RUN PROCESS
The following will provide the most efficient order along with tips to help run through the monitor
tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear
Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum
available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The
only monitors that will require attention are those that read "NO" under the OBD "CARB"
Readiness Status screen.
Front Wheel Drive
1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or out depending on conditions). The ambient (outside) temperature must be
between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining requirements.
2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the
requirements.
3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test
screen for this test to complete.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left
in drive for the test to run. If all parameters are met and the test still will not run, place your foot on
the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells
to update.
6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded.
This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No
Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater
monitor status. It should have switched to "YES". All other monitors should be completed before
running this test.
Rear Wheel Drive
1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either
indoors or outdoors depending on conditions). The ambient (outside) temperature must be between
18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining
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Readiness Monitor Information > Page 3495
requirements.
2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must
be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F)
of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test
screen on the DRB III(R) to determine the remaining requirements.
3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet
the requirements.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transmission vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be
left in drive for the test to run. If all parameters are met and the test will still not run, place your foot
on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF
cells to update.
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Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory
Technical Service Bulletin # 18-11-00 Date: 000728
A/T - DTC P1714 Stored in Memory
NUMBER: 18-11-00
GROUP: Vehicle Performance
DATE: July 28, 2000
SUBJECT: Low Voltage Clutch Protection - Added DTC - P1714 Low Battery Voltage
OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission
Control
Module (TCM) with new software.
MODELS: 1999 (FJ) Avenger/Sebring 1999 (GS)Chrysler Voyager (European Market) 1999
(JA)Cirrus/Stratus/Breeze 1999 (JX)Sebring Convertible 1999 (LH)Concorde/Intrepid/LHS/300M
1999 (NS)Town & Country/Caravan/Voyager 1999 (PR)Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE
AUTOMATIC TRANSAXLE BUILT PRIOR TO:
DISCUSSION:
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Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3501
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3502
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3503
Operation of vehicles with low battery voltage may result in the transaxle overdrive clutch becoming
distressed. Conditions such as an inoperative charging system or excess voltage drop to the TCM
circuits may be causes for low voltage. The software released by this Technical Service Bulletin
provides protection to the overdrive clutch and adds a new DTC - P1714 LOW BATTERY
VOLTAGE for these models. Diagnostic procedures relating to P1714 are included for your
reference.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED, THE SOFTWARE
OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION
LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS
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18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3504
AS NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
NOTE:
THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE
MDS2 SYSTEM MUST BE OPERATING AT CIS CD2063 OR HIGHER.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-51-90 Module Reprogram 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Symptom: P1714-LOW BATTERY VOLTAGE
When Monitored and Set Condition:
P1714-LOW BATTERY VOLTAGE
When Monitored: With the engine running and the TCM has closed the Transmission Control
Relay.
Set Condition: If battery voltage at TCM Transmission Control Relay Output Sense circuit is less
than 10.0 volts for 15 seconds. *P-1714 generally indicates a gradually falling battery voltage or
resistive connections to the TCM.
Possible Causes
RELATED CHARGING SYSTEM DTCS INTERMITTENT WIRING AND CONNECTORS FUSED
B+ CIRCUIT OPEN OR HIGH RESISTANCE GROUND CIRCUIT OPEN OR HIGH RESISTANCE
TRANS CONTROL RELAY OUTPUT TO TCM OPEN OR HIGH RESISTANCE TRANSMISSION
CONTROL RELAY OPEN OR HIGH RESISTANCE TCM - LOW BATTERY VOLTAGE
Repair Procedure
1. Log onto the MDS2 system.
2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and
switch the ignition key to "ON".
3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN
MENU SCREEN.
4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU
SCREEN.
NOTE:
ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE
"CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY
THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2
SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO
BEGIN SESSION.
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18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3505
5. Push the FLASH tab on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
7. Select the new software part number with the light pen and click UPDATE CONTROLLER
SOFTWARE.
8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
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Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
24-10-99A > Aug > 99 > PCM - A/C System Blows Warm Air Intermittently.
PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - A/C System
Blows Warm Air Intermittently.
NUMBER: 24-10-99 Rev. A
GROUP: Heating And A/C
DATE: Aug. 20, 1999
THIS BULLETIN SUPERCEDES TECHNICAL SERVICE BULLETIN 24-10-99 DATED MAY 28,
1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND EXCLUDES CERTAIN ENGINE APPLICATIONS.
SUBJECT: A/C System Blows Warm Air Intermittently
OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control
Module (PCM) with new software (calibration changes).
MODELS:
1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market)
**NOTE:
THIS INFORMATION APPLIES TO ALL APPLICATIONS EXCEPT NS MODELS WITH A 3.0L
ENGINE AND GS MODELS WITH A 2.4L/4 SPEED EATX COMBINATION.**
SYMPTOM/CONDITION:
Some vehicles may exhibit an intermittent condition where the A/C system blows warm air after the
A/C system had been working properly. This could occur when the vehicle is travelling above 40
mph and the engine is NOT in an overheat condition. The discharge vents may suddenly blow
warm air continuously until the A/C select button is re-selected or the vehicle is re-started. Once
the A/C select button is re-selected or vehicle is re-started, the A/C system will function normally
again.
DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB
III(R) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems
are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the
repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are
present and the customer has described the above symptoms, perform the Repair Procedure.
NOTE:
WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE
LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED
CONTROLLERS AS NECESSARY.
PARTS REQUIRED:
1 04669020 Label, Authorized Software Update
1 04275086 Label, Authorized Modification
EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7OOO/7001 J1962 Cable
1 MDS2
NOTE:
THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE
MDS2 SYSTEM MUST BE OPERATING AT CIS CD2034 OR HIGHER.
REPAIR PROCEDURE:
1. Log onto the MDS2 system.
2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and
switch the ignition key to "ON"
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24-10-99A > Aug > 99 > PCM - A/C System Blows Warm Air Intermittently. > Page 3510
3. Using the arrow keys, select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN
MENU SCREEN.
4. Using the arrow keys, select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU
SCREEN.
NOTE:
ONCE MDS2, DRB III(R) AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE
CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY
THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2
SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO
BEGIN SESSION.
5. Push the FLASH tab on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
7. Select the new software part number with the light pen and click UPDATE CONTROLLER
SOFTWARE.
8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
24-10-99A > Aug > 99 > PCM - A/C System Blows Warm Air Intermittently. > Page 3511
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-44-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information
Technical Service Bulletin # 25-02-98 Date: 981023
I/M Testing - OBDII CARB Readiness Monitor Information
NO: 25-02-98
GROUP: Emissions
DATE: Oct. 23, 1998
SUBJECT:
I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information
MODELS:
1996 - 1999 (AB) Ram Van/Wagon
1996 - 1999 (AN) Dakota
1996 - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
1996 - 1999 (FJ) Avenger/Sebring/Talon
1996 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1995 - 1999 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper Roadster/Coupe
1997 - 1999 (TJ) Wrangler
1999 (WJ) Grand Cherokee
1996 - 1999 (XJ) Cherokee
1996 - 1998 (ZJ) Grand Cherokee
NOTE:
THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE
ENGINES.
DISCUSSION:
Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a
prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their
self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or
more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their
tests.
It is important to understand that the MIL will not be illuminated because OBD Readiness reads
"NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions
system occurs. It is possible to have MIL illumination for a detected failure while at the same time
having a "NO" for an OBO Readiness monitor.
NOTE:
MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER
DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS
BULLETIN.
OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM
replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items
occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for
OBD Readiness.
Some customers may be directed back to their dealers for assistance when an I/M test station has
not allowed an I/M test due to Readiness status. The following procedures will help technicians
efficiently run the Readiness tests so an owner can have their I/M test completed.
EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH7000/7001 J1962Cable
1 CH7OlO J1962 MMC Cable
POLICY: Reimbursable within the provisions of the warranty.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3516
TIME ALLOWANCE:
Labor Operation No: 25-01-01-91 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
This bulletin involves operating the vehicle under specific parameters to run or complete the OBD
monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions
application. In addition, the parameters to run each monitor will vary.
Preliminary Checks
1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate
as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit.
2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year
diagnostics, engine, DTC's and related functions, read DTC's.
3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the
engine running.
NOTE:
EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS
FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE
ATTEMPTING TO RUN THE MONITORS.
OBD "CARB" Readiness Check
1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status.
2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO"
tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned
to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read
"YES".
NOTE:
THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES
APPLICABLE FOR THE VEHICLE BEING WORKED ON.
The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to
run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The
pre-test/monitor test screen lists all the preliminary parameters that must be met along with the
running parameters for that specific monitor to run. An example of one screen is shown in Figure 1.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3517
NOTE:
1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN.
PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE
MONITORS RUN WILL BE SIMILAR.
The following explains how to interpret each section of the screen:
PRE-TEST REQUIREMENTS
The pre-test requirements include all the operating parameters that must be met before the actual
test can run. The vehicle must be operated until each item within the pre-test section are fulfilled.
LOW VALUE/HIGH VALUE/BAR GRAPH
The low value/high value provides the minimum and maximum operating conditions for each item
(ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when
the lowest value required for each item is met. This provides a visual indication that the parameters
are being met. The vehicle should be driven until most of each pre-test bar graph is filled.
MONITOR REQUIREMENTS
Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in
the monitor requirements section for the monitors to begin running. As the monitor begins to run,
the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle
operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician
must determine if the pre-test requirements or the monitor requirements have fallen outside the
window for the test and the vehicle must be driven accordingly for the test to restart. When the
monitor completes its test, the DRB III(R) will beep 3 consecutive times.
NOTE:
THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE
PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR
SCREEN FOR THIS MONITOR.
MONITOR RUN PROCESS
The following will provide the most efficient order along with tips to help run through the monitor
tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear
Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum
available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The
only monitors that will require attention are those that read "NO" under the OBD "CARB"
Readiness Status screen.
Front Wheel Drive
1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or out depending on conditions). The ambient (outside) temperature must be
between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining requirements.
2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the
requirements.
3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test
screen for this test to complete.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left
in drive for the test to run. If all parameters are met and the test still will not run, place your foot on
the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells
to update.
6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded.
This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No
Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater
monitor status. It should have switched to "YES". All other monitors should be completed before
running this test.
Rear Wheel Drive
1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either
indoors or outdoors depending on conditions). The ambient (outside) temperature must be between
18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining
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Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
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25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 3518
requirements.
2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must
be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F)
of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test
screen on the DRB III(R) to determine the remaining requirements.
3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet
the requirements.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transmission vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be
left in drive for the test to run. If all parameters are met and the test will still not run, place your foot
on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF
cells to update.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory
Technical Service Bulletin # 18-11-00 Date: 000728
A/T - DTC P1714 Stored in Memory
NUMBER: 18-11-00
GROUP: Vehicle Performance
DATE: July 28, 2000
SUBJECT: Low Voltage Clutch Protection - Added DTC - P1714 Low Battery Voltage
OVERVIEW: This bulletin involves selectively erasing and reprogramming the Transmission
Control
Module (TCM) with new software.
MODELS: 1999 (FJ) Avenger/Sebring 1999 (GS)Chrysler Voyager (European Market) 1999
(JA)Cirrus/Stratus/Breeze 1999 (JX)Sebring Convertible 1999 (LH)Concorde/Intrepid/LHS/300M
1999 (NS)Town & Country/Caravan/Voyager 1999 (PR)Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE
AUTOMATIC TRANSAXLE BUILT PRIOR TO:
DISCUSSION:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3524
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3525
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3526
Operation of vehicles with low battery voltage may result in the transaxle overdrive clutch becoming
distressed. Conditions such as an inoperative charging system or excess voltage drop to the TCM
circuits may be causes for low voltage. The software released by this Technical Service Bulletin
provides protection to the overdrive clutch and adds a new DTC - P1714 LOW BATTERY
VOLTAGE for these models. Diagnostic procedures relating to P1714 are included for your
reference.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED, THE SOFTWARE
OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION
LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3527
AS NECESSARY.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
NOTE:
THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE
MDS2 SYSTEM MUST BE OPERATING AT CIS CD2063 OR HIGHER.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-51-90 Module Reprogram 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Symptom: P1714-LOW BATTERY VOLTAGE
When Monitored and Set Condition:
P1714-LOW BATTERY VOLTAGE
When Monitored: With the engine running and the TCM has closed the Transmission Control
Relay.
Set Condition: If battery voltage at TCM Transmission Control Relay Output Sense circuit is less
than 10.0 volts for 15 seconds. *P-1714 generally indicates a gradually falling battery voltage or
resistive connections to the TCM.
Possible Causes
RELATED CHARGING SYSTEM DTCS INTERMITTENT WIRING AND CONNECTORS FUSED
B+ CIRCUIT OPEN OR HIGH RESISTANCE GROUND CIRCUIT OPEN OR HIGH RESISTANCE
TRANS CONTROL RELAY OUTPUT TO TCM OPEN OR HIGH RESISTANCE TRANSMISSION
CONTROL RELAY OPEN OR HIGH RESISTANCE TCM - LOW BATTERY VOLTAGE
Repair Procedure
1. Log onto the MDS2 system.
2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and
switch the ignition key to "ON".
3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN
MENU SCREEN.
4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU
SCREEN.
NOTE:
ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE
"CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY
THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2
SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO
BEGIN SESSION.
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Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-11-00 > Jul > 00 > A/T - DTC P1714 Stored in Memory > Page 3528
5. Push the FLASH tab on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
7. Select the new software part number with the light pen and click UPDATE CONTROLLER
SOFTWARE.
8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
A604 (41TE) 4 Speed Transaxle
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations
A604 (41TE) 4 Speed Transaxle
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 21-15-99 > Oct > 99 > A/T - Case Porosity/Fluid
Seepage
Case: Customer Interest A/T - Case Porosity/Fluid Seepage
NUMBER: 21-15-99
GROUP: Transmission
DATE: Oct. 1, 1999
SUBJECT: Transaxle Seepage Mis-Diagnosis - Case Porosity
OVERVIEW: This bulletin involves properly identifying the seepage location (porosity) and if
applicable, using a peening process to seal the porous area of the transaxle case.
MODELS: 1999 (FJ) Avenger/Sebring 1999 (GS) Chrysler Voyager (International Market) 1999
(JA) Cirrus/Stratus/Breeze 1999 (JX) Sebring Convertible 1999 (NS) Town &
Country/Caravan/Voyager
SYMPTOM/CONDITION: Some vehicles may exhibit seepage from the transaxle case. This
seepage may be due to case porosity in the cooler boss area and can be mis-diagnosed as
leakage from the pan, or input speed sensor. Transaxles that may exhibit this condition have a web
of metal attaching the cooler bosses and the input speed sensor boss (Figure 1). This web forms a
circular pocket in that area.
DIAGNOSIS: Start the vehicle and warm the transaxle fluid to 93° C (200° F). Clean the transaxle
pan and the area around the input speed sensor. Pay particular attention to cleaning the boss area
between the cooler lines, above the input speed sensor (Figure 1). With a helper in the vehicle, set
the parking brake, place the transaxle in reverse, apply the service brake and raise the RPM to
approximately 1100 RPM for at least 3 minutes. Inspect the cooler line boss area just above the
input speed sensor (Figure 1). If seepage is noted from the pocket formed by the web of metal, the
following repair procedure can be used. If case seepage is not noted in this area, further diagnosis
will be required.
EQUIPMENT REQUIRED:
1 NPN Air Hammer
1 PH59 Snap-On Tapered Punch Or Equivalent
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 21-15-99 > Oct > 99 > A/T - Case Porosity/Fluid
Seepage > Page 3548
REPAIR PROCEDURE:
1. Remove components for clear access to the transaxle as follows:
FJ Models - Air intake hose (throttle body to airbox), air box cover & filter, and left cooling fan
module. JA/JX Models - Transaxle Control Module (TCM), TCM bracket and solenoid pack
electrical connector. NS/GS Models - Air intake hose at throttle body & resonator, airbox cover &
filter, and solenoid pack electrical connector.
2. Using a suitable air hammer and blunt punch attachment (Snap-On PH59 or equivalent), insert
the punch into the pocket formed by the web of metal (Figure 1).
3. Operate the air hammer for 15 to 20 seconds while moving the punch in a circular motion within
the pocket. Start in the center of the pocket and work outwards in a clockwise or counter clockwise
pattern.
4. Repeat step 3 and then reassemble the vehicle.
NOTE:
ONLY OPERATE THE AIR HAMMER IN 15 TO 20 SECOND INTERVALS.
5. Re-test the transaxle for leaks by performing the procedure listed in the diagnosis section.
6. If the leak is repaired, return the vehicle to the customer.
NOTE:
BE SURE TO CLEAN ANY REMAINING TRANSAXLE FLUID FROM THE VEHICLE TO
PREVENT CONTINUED DRIPPING ON THE GROUND.
7. If the area continues to leak, the transaxle will require replacement.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-00-20-92 0.7 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 21-15-99 > Oct > 99 > A/T - Case
Porosity/Fluid Seepage
Case: All Technical Service Bulletins A/T - Case Porosity/Fluid Seepage
NUMBER: 21-15-99
GROUP: Transmission
DATE: Oct. 1, 1999
SUBJECT: Transaxle Seepage Mis-Diagnosis - Case Porosity
OVERVIEW: This bulletin involves properly identifying the seepage location (porosity) and if
applicable, using a peening process to seal the porous area of the transaxle case.
MODELS: 1999 (FJ) Avenger/Sebring 1999 (GS) Chrysler Voyager (International Market) 1999
(JA) Cirrus/Stratus/Breeze 1999 (JX) Sebring Convertible 1999 (NS) Town &
Country/Caravan/Voyager
SYMPTOM/CONDITION: Some vehicles may exhibit seepage from the transaxle case. This
seepage may be due to case porosity in the cooler boss area and can be mis-diagnosed as
leakage from the pan, or input speed sensor. Transaxles that may exhibit this condition have a web
of metal attaching the cooler bosses and the input speed sensor boss (Figure 1). This web forms a
circular pocket in that area.
DIAGNOSIS: Start the vehicle and warm the transaxle fluid to 93° C (200° F). Clean the transaxle
pan and the area around the input speed sensor. Pay particular attention to cleaning the boss area
between the cooler lines, above the input speed sensor (Figure 1). With a helper in the vehicle, set
the parking brake, place the transaxle in reverse, apply the service brake and raise the RPM to
approximately 1100 RPM for at least 3 minutes. Inspect the cooler line boss area just above the
input speed sensor (Figure 1). If seepage is noted from the pocket formed by the web of metal, the
following repair procedure can be used. If case seepage is not noted in this area, further diagnosis
will be required.
EQUIPMENT REQUIRED:
1 NPN Air Hammer
1 PH59 Snap-On Tapered Punch Or Equivalent
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 21-15-99 > Oct > 99 > A/T - Case
Porosity/Fluid Seepage > Page 3554
REPAIR PROCEDURE:
1. Remove components for clear access to the transaxle as follows:
FJ Models - Air intake hose (throttle body to airbox), air box cover & filter, and left cooling fan
module. JA/JX Models - Transaxle Control Module (TCM), TCM bracket and solenoid pack
electrical connector. NS/GS Models - Air intake hose at throttle body & resonator, airbox cover &
filter, and solenoid pack electrical connector.
2. Using a suitable air hammer and blunt punch attachment (Snap-On PH59 or equivalent), insert
the punch into the pocket formed by the web of metal (Figure 1).
3. Operate the air hammer for 15 to 20 seconds while moving the punch in a circular motion within
the pocket. Start in the center of the pocket and work outwards in a clockwise or counter clockwise
pattern.
4. Repeat step 3 and then reassemble the vehicle.
NOTE:
ONLY OPERATE THE AIR HAMMER IN 15 TO 20 SECOND INTERVALS.
5. Re-test the transaxle for leaks by performing the procedure listed in the diagnosis section.
6. If the leak is repaired, return the vehicle to the customer.
NOTE:
BE SURE TO CLEAN ANY REMAINING TRANSAXLE FLUID FROM THE VEHICLE TO
PREVENT CONTINUED DRIPPING ON THE GROUND.
7. If the area continues to leak, the transaxle will require replacement.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 21-00-20-92 0.7 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Page 3555
Case: Specifications
Rear End Cover 175 in.lb
Transfer Plate To Case 105 in.lb
Vent Assembly 105 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Low Reverse Clutch
Clutch: Specifications
Low/Rev Clutch Select Reaction Plate 0.035 - 0.042 in
Clutch Retainer 45 in. lbs.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Low Reverse Clutch > Page 3560
Clutch: Specifications
Overdrive Clutch No Selection 0.053 - 0.125 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Low Reverse Clutch > Page 3561
Clutch: Specifications
Reverse Clutch Select Snap Ring 0.030 - 0.049 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Low Reverse Clutch > Page 3562
Clutch: Specifications
Two/Four Clutch No Selection 0.030 - 0.104 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Low Reverse Clutch > Page 3563
Clutch: Specifications
Underdrive Clutch Select Pressure Plate 0.036 - 0.058 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Specifications
Control Module: Specifications
Sixty-Way Connector 35 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Specifications > Page 3567
Transmission Control Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions
Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3570
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3571
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3572
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3573
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3574
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3575
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3576
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3577
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3578
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3579
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3580
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3581
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3582
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3583
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3584
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3585
Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3586
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 3587
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Component Information > Diagrams > Diagram Information and Instructions > Page 3588
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Page 3589
Control Module: Description and Operation
AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT
The electronic automatic transaxle control module and the PCM supply information to each other
through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the
information when adjusting the fuel and ignition strategy.
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Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Page 3590
Control Module: Service and Repair
OVERVIEW
Do not interchange Transmission Control Modules with previous year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed: Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
REMOVAL
Fig. 27
1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then
disconnect the 60 way connector on Transmission
Control Module.
Fig. 28
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Component Information > Diagrams > Page 3591
Fig. 29
2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28
and 29).
INSTALLATION
1. To install, reverse removal procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Differential Case, A/T > Component Information > Specifications
Differential Case: Specifications
Differential Cover 165 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Specifications
Extension Housing: Specifications
Extension Housing 21 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications
Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications
NUMBER: 21-010-06
GROUP: Transmission
DATE: April 14, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH
16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE
REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602)
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1989 - 2003 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AD) Ram Truck
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2004 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1990 - 1991 (AQ) Maserati
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2003 (BR/BE) Ram Truck
2004 - 2007 (CS) Pacifica
1998 - 2003 (DN) Durango
2002 - 2007 (DR/DH/D1) Ram Truck
2007 (DC) Ram 3500 Cab Chassis
1995 - 2000 (FJ) Sebring/Avenger/Talon
1996 - 2000 (CS) Chrysler Voyager (International Market)
2004 - 2007 (HB) Durango
1995 - 2000 (JA) Cirrus/Stratus/Breeze
2007 (JK) Wrangler
2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 3603
2007 (JS) Avenger/Sebring
1996 - 2000 (JX) Sebring Convertible
2002 - 2007 (KJ) Liberty
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M
2005 - 2007 (LX/LE) 300/Magnum/Charger
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2005 (PL) Neon
2002 - 2003 (PG) PT Cruiser (International Markets)
2001 - 2007 (PT) PT Cruiser
1997 - 2002 (PR) Prowler
2001 - 2007 (RG) Chrysler Voyager (International Markets)
2001 - 2007 (RS) Town & Country/Caravan/Voyager
1997 - 2006 (TJ) Wrangler
2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines
1999 - 2004 (WJ) Grand Cherokee
2005 - 2007 (WK/WH) Grand Cherokee
2006 - 2007 (XK/XH) Commander
1989 - 1995 (YJ) Wrangler
1996 - 1998 (ZG) Grand Cherokee (International Markets)
1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire
transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG
vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission
(sales code DGJ).
DISCUSSION:
ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions.
ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions
EXCEPT FOR THOSE NOTED ABOVE.
NOTE:
ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE
ANY OTHER FLUID.
NOTE:
ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be
used to top off vehicles that used ATF+3, ATF+2, or ATF+.
NOTE:
If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid
maintenance schedules listed for that model does not change. The service interval currently in
effect for a given model should continue to be followed. Refer to the Service or Owners manual for
maintenance schedule directions.
In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to
use ATF+4.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - ATF+4 Fluid Usage/Applications > Page 3604
BENEFITS
^ Better anti-wear properties
^ Improved rust/corrosion prevention
^ Controls oxidation
^ Eliminates deposits
^ Controls friction
^ Retains anti-foaming properties
^ Superior properties for low temperature operation
FLUID COLOR
Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not
permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a
unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer
indicators of fluid condition and do not necessarily support a fluid change.
PARTS REQUIRED:
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid
31TH ....................................................................................................................................................
............................................................. 8.0L (8.5 Qt) 41TE .................................................................
................................................................................................................................................ 8.6L
(9.1 Qt)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 3607
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type Type ............................................................................................................
....................................................... MOPAR ATF +4 Type 9602 or Equivalent
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Page 3608
Fluid - A/T: Service Precautions
DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission
damage may occur.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level and Condition Check
Fluid - A/T: Service and Repair Fluid Level and Condition Check
NOTE: The transmission and differential utilize the same fluid sump, which require Automatic
Transmission Fluid (ATF+4/Type 9602).
NOTE: The transmission fluid level should be inspected at least every six months.
FLUID LEVEL CHECK
The transmission sump has a dipstick to check oil similar to most automatic transmissions. It is
located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing.
Fig. 7
The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P
Park to be sure that the fluid level check is accurate. The engine should be running at idle speed
for at least one minute, with the vehicle on level ground. At normal operating temperature
(approximately 82°C or 180°F), the fluid level is correct if it is in the HOT region (cross-hatched
area) on the oil level indicator (Fig. 7). The fluid level will be approximately one-quarter inch above
the lower hole of the dipstick at 70°F fluid temperature.
FLUID LEVEL CHECK USING DRB
NOTE: Engine and Transaxle should be at normal operating temperature before performing this
procedure.
1. Start engine and apply parking brake. 2. Hook up DRBIII scan tool and select transmission. 3.
Select sensors. 4. Read the transmission temperature value. 5. Compare the fluid temperature
value with the chart.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level and Condition Check > Page 3611
TRANSMISSION FLUID TEMPERATURE CHART
6. Adjust transmission fluid level shown on the dipstick according to the chart. 7. Check
transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump
to take in air along with the fluid. As in
any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build
up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much
fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In
either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid
escaping from the transaxle vent where it may be mistaken for a leak. Along with fluid level, it is
important to check the condition of the fluid. When the fluid smells burned, and is contaminated
with metal or friction material particles, a complete transaxle recondition is needed. Be sure to
examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a
sample for a double check. After the fluid has been checked, seat the dipstick fully to seal out water
and dirt.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level and Condition Check > Page 3612
Fluid - A/T: Service and Repair Fluid and Filter Service
NOTE: Refer to Maintenance, or the vehicle owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at the time of the transmission oil change. The
magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2.
Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body and tighten
retaining screws to 5 Nm (40 inch lbs.). 4. Clean the oil pan and magnet. Reinstall pan using new
MOPAR Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four
quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening.
6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
Fig. 8
7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to
3 mm (1/8 inch) below the "ADD" mark on the
dipstick.
TRANSMISSION FLUID TEMPERATURE CHART
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level and Condition Check > Page 3613
8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 9.
To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick
opening
ALTERNATIVE SERVICE METHODS (FLUID ONLY)
TRANSAXLE FLUID EXCHANGER METHOD
CAUTION The use of any fluid exchanger that introduces additives into the transaxle is not
recommended.
1. To perform the transaxle fluid exchange, the transaxle must be at operating temperature. Drive
the vehicle until it reaches full operating
temperature.
2. Obtain a suitable transaxle fluid exchanger and verify the tank is clean and dry. 3. Fill the tank to
the recommended fill capacity with MOPAR ATF+4 Type 9602. 4. Connect the machine to the
vehicle following the manufacturers instructions. Perform the exchange procedure following the
instructions provided
with the machine.
5. Once machine has completed the fluid exchange. Check the fluid level and condition and fill to
proper level with MOPAR ATF+4 Type 9602.
Refer to Fluid Level and Condition Check for the proper fluid "top-off" procedure.
NOTE: Verify that the transaxle cooler lines are tightened to proper specifications. Cooler line
torque specification is 2 Nm (18 inch lbs.).
DIPSTICK TUBE FLUID SUCTION METHOD 1. When performing the fluid suction method, make
sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (macular or equivalent). 3. Insert the fluid suction line
into the dipstick tube.
NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5.
Remove the suction line from the dipstick tube. 6. Pour four quarts of MOPAR ATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at
least one minute. Then, with parking and service brakes applied, move selector lever momentarily
to each
position, ending in the park or neutral position.
8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to
3 mm (1/8 inch) below the "ADD" mark on the
dipstick.
9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.).
10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the
dipstick opening.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair
Fluid Filter - A/T: Service and Repair
NOTE: Refer to Maintenance, or the vehicle owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602
should be used. A filter change should be made at the time of the transmission oil change. The
magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth.
NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2.
Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body and tighten
retaining screws to 5 Nm (40 inch lbs.). 4. Clean the oil pan and magnet. Reinstall pan using new
MOPAR Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four
quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening.
6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
Fig. 8
7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to
3 mm (1/8 inch) below the "ADD" mark on the
dipstick.
TRANSMISSION FLUID TEMPERATURE CHART
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Page 3617
8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F). 9.
To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick
opening
ALTERNATIVE SERVICE METHODS (FLUID ONLY)
TRANSAXLE FLUID EXCHANGER METHOD
CAUTION The use of any fluid exchanger that introduces additives into the transaxle is not
recommended.
1. To perform the transaxle fluid exchange, the transaxle must be at operating temperature. Drive
the vehicle until it reaches full operating
temperature.
2. Obtain a suitable transaxle fluid exchanger and verify the tank is clean and dry. 3. Fill the tank to
the recommended fill capacity with MOPAR ATF+4 Type 9602. 4. Connect the machine to the
vehicle following the manufacturers instructions. Perform the exchange procedure following the
instructions provided
with the machine.
5. Once machine has completed the fluid exchange. Check the fluid level and condition and fill to
proper level with MOPAR ATF+4 Type 9602.
Refer to Fluid Level and Condition Check for the proper fluid "top-off" procedure.
NOTE: Verify that the transaxle cooler lines are tightened to proper specifications. Cooler line
torque specification is 2 Nm (18 inch lbs.).
DIPSTICK TUBE FLUID SUCTION METHOD 1. When performing the fluid suction method, make
sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction
method, use a suitable fluid suction device (macular or equivalent). 3. Insert the fluid suction line
into the dipstick tube.
NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5.
Remove the suction line from the dipstick tube. 6. Pour four quarts of MOPAR ATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at
least one minute. Then, with parking and service brakes applied, move selector lever momentarily
to each
position, ending in the park or neutral position.
8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to
3 mm (1/8 inch) below the "ADD" mark on the
dipstick.
9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.).
10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the
dipstick opening.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > A/T Oil Cooler Line Hose Clamp - Revised
Fluid Line/Hose: Technical Service Bulletins A/T Oil Cooler Line Hose Clamp - Revised
NUMBER: 07-006-01
GROUP: Cooling
DATE: Nov. 11, 2001
SUBJECT: Transmission Oil Cooler Line Hose Clamp Service
OVERVIEW: This bulletin provides revised transmission oil cooler hose clamp information.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
DISCUSSION:
A revised transmission oil cooler hose clamp is now available and should be used any time it is
necessary to separate oil cooler hose connections. Tighten the clamp(s) to 3.2 Nm (28 in. lbs.).
Transmission oil cooler hoses should be replaced only it they are damaged.
NOTE:
WEATHERED SURFACE APPEARANCE ON TRANSMISSION OIL COOLER HOSES IS A
NORMAL CONDITION AND WILL NOT IMPAIR THEIR ABILITY TO SEAL.
PARTS REQUIRED:
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Page 3622
Fluid Line/Hose: Specifications
Oil Cooler Line Fittings 105 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Specifications
Fluid Pan: Specifications
TORQUE SPECIFICATIONS
Bolt, Oil Pan-to-Case ...........................................................................................................................
..................................................... 19 Nm (14 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Specifications > Dimensional
Fluid Pump: Specifications
Oil Pump Outer Gear To Pocket 0.0018 - 0.0056 in
Outer Gear Side Clearance 0.0008 - 0.0018 in
Inner Gear Side Clearance 0.0008 - 0.0018 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Specifications > Dimensional > Page 3630
Fluid Pump: Specifications
Oil Pump To Case Bolts 20 ft.lb
Reaction Shaft Bolts 20 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Input Shaft, A/T >
Component Information > Specifications
Input Shaft: Specifications
Input Shaft End Play 0.005 - 0.025 in
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T >
Component Information > Specifications
Output Shaft: Specifications
Output Gear Bolt 200 ft.lb
Stirrup Retainer 17 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Locations
Autostick/Overdrive Off
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Locations > Page 3640
Autostick/Overdrive Switch Connector Pin Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Specifications
Control Module: Specifications
Sixty-Way Connector 35 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Specifications > Page 3645
Transmission Control Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions
Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3648
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3649
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3650
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3651
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3652
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3653
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3654
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3655
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3656
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3657
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3658
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3659
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3660
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3661
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3662
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3663
Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3664
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3665
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3666
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Page 3667
Control Module: Description and Operation
AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT
The electronic automatic transaxle control module and the PCM supply information to each other
through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the
information when adjusting the fuel and ignition strategy.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Page 3668
Control Module: Service and Repair
OVERVIEW
Do not interchange Transmission Control Modules with previous year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed: Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
REMOVAL
Fig. 27
1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then
disconnect the 60 way connector on Transmission
Control Module.
Fig. 28
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Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Page 3669
Fig. 29
2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28
and 29).
INSTALLATION
1. To install, reverse removal procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations > Page 3673
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations > Page 3674
Transmission Control System Relay: Diagrams
Power Distribution Center
Transmission Control Relay (EATX)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations > Page 3675
Transmission Control System Relay: Description and Operation
TRANSMISSION CONTROL RELAY
The transmission control relay is located in the Power Distribution Center (PDC) on the left side of
the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is
used to supply power to the solenoid pack when the transmission is in normal operating mode.
When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in
mode. After a controller reset (ignition key turned to the run position or after cranking engine), the
TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for
no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack
pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify
that the voltage is greater than 3 volts.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > A/T Pan Gasket - Reusable Design/Installation
Technical Service Bulletin # 21-05-99A Date: 990903
A/T Pan Gasket - Reusable Design/Installation
NUMBER: 21-05-99 Rev. A
GROUP: Transmission
DATE: Sep. 03, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5,
1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL
COVERAGE.
SUBJECT: Reusable Automatic Transmission Oil Pan Gasket
OVERVIEW: This bulletin announces availability and installation of a reusable automatic
transmission oil pan gasket.
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
**1989** - 1993 (AG) Daytona
**1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - **2000** (FJ) Sebring/Avenger/Talon
1996 - **2000** (GS) Chrysler Voyager (European Market)
1995 - **2000** (JA) Cirrus/Stratus/Breeze
1996 - **2000** (JX) Sebring Convertible
**1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M**
1996 - **2000** (NS) Town & Country/Caravan/Voyager
**1995 - 2000 (PL) Neon**
**1997 - 2000 (PR) Prowler**
DISCUSSION:
A reusable silicone gasket has been developed to replace the RTV method of sealing the
automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change
intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is
recommended that this gasket be used in all applications.
NOTE:
THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES.
PARTS REQUIRED:
**1 05011113AA Gasket, Transmission Oil Pan, 31TH**
**1 05011114AA Gasket, Transmission Oil Pan, 42LE**
1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE
POLICY: INFORMATION ONLY
POLICY: Information Only
Installation Procedure
1. With oil pan removed from transmission case for routine service or transmission repair proceed
to step # 2.
2. Clean any residue from oil pan and magnet.
3. Replace O-ring and filter on bottom of valve body.
4. Using a plastic or wooden scraper, remove old RTV from transmission case rails.
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Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > A/T Pan Gasket - Reusable Design/Installation > Page 3680
CAUTION:
ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD
GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING
THESE COMPONENTS.
5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails.
6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission
case. Tighten oil pan bolts to 19 Nm (165 in lbs.).
7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or
MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles.
CAUTION:
DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES
FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Page 3681
Seals and Gaskets: Service and Repair
REMOVAL
Fig. 48
INSTALLATION
Fig. 49
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations
Autostick/Overdrive Off
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3686
Autostick/Overdrive Switch Connector Pin Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations
Transmission Mode Switch: Locations
For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3690
Transmission Mode Switch: Diagrams
For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission
Range Sensor - Production Change
Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission
Range Sensor - Production Change > Page 3695
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission
Range Sensor - Production Change > Page 3696
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3697
Transmission Range Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3698
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3699
Transmission Position Switch/Sensor: Description and Operation
Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical
TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT
The park/neutral switch is located on the transaxle housing.
If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral.
This input is used to determine idle speed (varying with gear selection) and ignition timing advance.
The park neutral switch is sometimes referred to as the neutral safety switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3700
Transmission Position Switch/Sensor: Service and Repair
The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
Fig. 20
3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission
range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8.
Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
Fig. 21
11. Place valve body on workbench (Fig. 21).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3701
Fig. 22
12. Remove TRS retaining screw (Fig. 22).
Fig. 23
13. Remove manual shaft seal (Fig. 23).
Fig. 24
14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24).
INSTALLATION
1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.)
Reseal transaxle oil pan using RTV.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3710
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control >
Page 3716
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3717
Transmission Speed Sensor: Specifications
Speed Sensor Input 20 ft.lb
Output 20 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3718
Input Speed Sensor/Output Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 3721
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor
Transmission Speed Sensor: Service and Repair Input Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 25
The input speed sensor is located to the left of the manual shift lever (Fig. 25).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor > Page 3724
Transmission Speed Sensor: Service and Repair Output Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 26
The output speed sensor is located to the right of the manual shift lever (Fig. 26).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations
A604 (41TE) 4 Speed Transaxle
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair
Shifter A/T: Service and Repair
REMOVAL
Fig. 14
1. Remove shift cable from lever (Fig. 14).
Fig. 15
2. Loosen the lever mounting bolt (Fig. 15). Do not remove bolt (not necessary). 3. Pull up on lever
and remove.
INSTALLATION
1. For installation, reverse removal procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments
Shift Cable: Adjustments
Lift and rotate the gearshift hand lever into the park (P) gate position and remove the ignition key.
This confirms the shift lever is in the gated park (P) position. After confirming the park gate position'
turn the ignition switch. If the starter will operate, the park gate position is correct. Move the shift
lever into the neutral (N) position. If the starter will operate in this position, the linkage is properly
adjusted. If the starter fails to operate in either position, linkage adjustment is required. 1. Park the
vehicle on level ground and set the parking brake. 2. Place the gearshift lever in park (P) gate
position and remove key.
Fig. 13
3. Loosen the cable adjustment screw at the transaxle operating lever (Fig. 13). 4. Pull the
transaxle operating lever fully forward to the park detent position. 5. Release the park brake, then
rock the vehicle to assure it is in park lock. Reset the park brake. 6. Tighten the cable adjustment
screw to 8 Nm (70 inch lbs.). Gearshift cable should now be properly adjusted. 7. Check
adjustment by using the preceding procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 3735
Shift Cable: Service and Repair
REMOVAL
Fig. 9
1. Remove cable eyelet attachment from transaxle operating lever pin (Fig. 9).
Fig. 10
Fig. 11
2. Using pliers, squeeze ears of cable conduit attachment at mounting bracket (Fig. 10) and push
through hole to remove (Fig. 11).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 3736
Fig. 12
3. Remove the under instrument panel silencer (Fig. 12). 4. At the steering column attachment,
remove the cable eyelet attachment from the shift lever pin. 5. Using pliers, squeeze ears of cable
attachment at mounting bracket then push through hole to remove. 6. Unseat the dash grommet
and remove the cable from the vehicle.
INSTALLATION
1. Install cable into steering column attachment bracket. Verify conduit ears are fully engaged.
Verify cable does not interfere with brake pedal
actuation.
2. Attach cable eyelet fitting onto shift lever pin. 3. Insert transaxle end of cable through dash panel
hole and fully seat grommet 4. Install instrument panel silencer. Verify gearshift cable is routed
through the slot in the silencer.
CAUTION: Failure to route the cable properly at the silencer may cause brake pedal interference.
5. Attach transaxle end of cable to the mounting bracket on the transaxle. Assure the conduit
attachment ears are fully seated. 6. Attach cable eyelet fitting onto the transaxle operating lever. 7.
Complete adjustment using the gearshift cable adjustment procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Page 3740
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Page 3741
Transmission Control System Relay: Diagrams
Power Distribution Center
Transmission Control Relay (EATX)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Page 3742
Transmission Control System Relay: Description and Operation
TRANSMISSION CONTROL RELAY
The transmission control relay is located in the Power Distribution Center (PDC) on the left side of
the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is
used to supply power to the solenoid pack when the transmission is in normal operating mode.
When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in
mode. After a controller reset (ignition key turned to the run position or after cranking engine), the
TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for
no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack
pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify
that the voltage is greater than 3 volts.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Description and Operation
Transmission Cooler: Description and Operation
Auxiliary Transmission Oil Cooler
The primary transmission oil cooler is an internal oil-to-coolant type, mounted in the radiator left
tank. Also, an auxiliary oil-to-air type cooler is mounted in front of the A/C condenser. Use only
approved transmission oil cooler hose. Since these are molded to fit space available, molded
hoses are recommended.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Service and Repair > Cooler Flow Check
Transmission Cooler: Service and Repair Cooler Flow Check
After the new or repaired transmission has been installed, fill to the proper level with MOPAR
ATF+4 (Type 9602) automatic transmission fluid. The volume should be checked using the
following procedure: 1. Disconnect the From cooler line at the transmission and place a collecting
container under the disconnected line.
CAUTION: With the fluid set at the proper level, fluid collection should not exceed 1 quart or
internal damage to the transmission may occur.
2. Run the engine at curb idle speed, with the shift selector in neutral. 3. If fluid flow is intermittent
or it takes more than 20 seconds to collect one quart of ATF, disconnect the To Cooler line at the
transaxle. 4. Refill the transaxle to proper level and recheck pump volume. 5. If flow is found to be
within acceptable limits, replace the cooler. Then fill transmission to the proper level, using MOPAR
ATF+ 3 (Type 9602)
automatic transmission fluid.
6. If fluid flow is still found to be inadequate, check the line pressure using the Transaxle Hydraulic
Pressure Test procedure. 7. Check the cooler for debris on the external surfaces. Clean as
necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Service and Repair > Cooler Flow Check > Page 3748
Transmission Cooler: Service and Repair Flushing Coolers and Tubes
When a transaxle failure has contaminated the fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also. The torque converter must also be replaced
with an exchange unit. This will insure that metal particles or sludged oil are not later transferred
back into the reconditioned (or replaced) transaxle. The recommended procedure for flushing the
transaxle cooler is to use Tool 6906A Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1-1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES.
- KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, AND OTHER IGNITION SOURCES AWAY
FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES.
KEEP A CLASS (B) FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE
USED.
- KEEP THE AREA WELL VENTILATED.
- DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE
CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS. REMOVE
CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER. SEEK
MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
1. Remove cover plate filler plug on Tool 6906A. Fill reservoir 1/2 to 3/4 full of fresh flushing
solution. Flushing solvents are petroleum based
solutions generally used to clean automatic transmission components. DO NOT use solvents
containing acids, water, gasoline, or any other corrosive liquids.
2. Reinstall filler plug on Tool 6906A. 3. Verify pump power switch is turned OFF. Connect red
alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4.
Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush.
5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR
return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s)
and lines. Monitor pressure readings and clear return lines. Pressure readings should
stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped
with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler.
8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect
CLEAR return line at cover plate, and place it in a drain pan.
10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump
OFF. 11. Place CLEAR suction line into a one quart container of MOPAR ATF+4 Type 9602
automatic transmission fluid. 12. Turn pump ON until all transmission fluid is removed from the one
quart container and lines. This purges any residual cleaning solvent from the
transmission cooler and lines. Turn pump OFF.
13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove
flushing adapters from cooler lines.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Locations
Transmission Mode Switch: Locations
For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Locations > Page 3752
Transmission Mode Switch: Diagrams
For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T
> Component Information > Service and Repair
Transmission Mount: Service and Repair
Refer to Engine; Drive Belts, Mounts, Brackets and Accessories; Engine Mount; Service and
Repair for procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production
Change
Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production
Change > Page 3760
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Transmission Range Sensor - Production
Change > Page 3761
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3762
Transmission Range Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3763
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3764
Transmission Position Switch/Sensor: Description and Operation
Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical
TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT
The park/neutral switch is located on the transaxle housing.
If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral.
This input is used to determine idle speed (varying with gear selection) and ignition timing advance.
The park neutral switch is sometimes referred to as the neutral safety switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3765
Transmission Position Switch/Sensor: Service and Repair
The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
Fig. 20
3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission
range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8.
Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
Fig. 21
11. Place valve body on workbench (Fig. 21).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Page 3766
Fig. 22
12. Remove TRS retaining screw (Fig. 22).
Fig. 23
13. Remove manual shaft seal (Fig. 23).
Fig. 24
14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24).
INSTALLATION
1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.)
Reseal transaxle oil pan using RTV.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure
Test Port, A/T > Component Information > Locations
Pressure Port Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3778
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 3784
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Page 3785
Transmission Speed Sensor: Specifications
Speed Sensor Input 20 ft.lb
Output 20 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Page 3786
Input Speed Sensor/Output Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Input Speed Sensor
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page 3789
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Input Sensor
Transmission Speed Sensor: Service and Repair Input Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 25
The input speed sensor is located to the left of the manual shift lever (Fig. 25).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Input Sensor > Page 3792
Transmission Speed Sensor: Service and Repair Output Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 26
The output speed sensor is located to the right of the manual shift lever (Fig. 26).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Specifications
Valve Body: Specifications
Valve Body To Case Bolts ...................................................................................................................
............................................... 12 Nm (105 inch lbs.) Valve Body Bolts ..............................................
...................................................................................................................................... 5 Nm (45 inch
lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Specifications > Page 3796
A604 (41TE) 4 Speed Transaxle
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Specifications > Page 3797
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation
Valve Body: Service and Repair Removal and Installation
REMOVAL
NOTE: To ease removal of the valve body, turn the manual valve lever fully clockwise.
Refer to figures 30 through 36 for procedures.
Fig. 30
Fig. 31
Fig. 32
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 3800
Fig. 33
Fig. 34
Fig. 35
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 3801
Fig. 36
INSTALLATION
To install valve body, reverse removal procedure
CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve
body is mishandled or dropped.
NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise.
Guide park rod rollers into guide bracket, while shifting manual lever assembly out of the
installation position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 3802
Valve Body: Service and Repair Disassembly and Assembly
Refer to Figures 50 through 61 for procedure.
Fig. 50
Fig. 51
Fig. 52
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 3803
Fig. 53
Fig. 54
Fig. 55
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 3804
Fig. 56
Fig. 57
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 3805
Fig. 58
Fig. 59
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 3806
Fig. 60
Fig. 61
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 3807
Valve Body: Service and Repair Cleaning and Inspection
CLEANING VALVE BODY
Prior to removing any transaxle parts, plug all openings and clean unit, preferably by steam.
Cleanliness through entire disassembly and assembly cannot be overemphasized. When
disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do
not wipe parts with shop towels. All mating surfaces in the transaxles are accurately machined;
therefore, careful handling of all parts must be exercised to avoid nicks or burrs.
NOTE: Tag all springs, as they are removed, for reassembly identification.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 3808
Valve Body: Service and Repair Solenoid Assembly Replacement
REMOVAL
Input Speed Sensor Removed
Remove Sound Cover
Remove Attaching Screws
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 3809
Remove Solenoid Assembly
INSTALLATION
To install solenoid assembly, reverse removal procedure. Tighten screws to 12 Nm (105 inch lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Oil Capacity
Capacity ...............................................................................................................................................
......................................................... 1.9L (4.0 Pints)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 3815
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Grade ...................................................................................................................................................
................................................................... API GL-5
Viscosity ..............................................................................................................................................
..................................................................... 80W-90
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Page 3816
Fluid - Differential: Service Precautions
DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Description and Operation
Axle Shaft: Description and Operation
Vehicles equipped with either an automatic or manual transmission uses an unequal length
driveshaft system.
Vehicles equipped with automatic transaxles use a solid short interconnecting shaft on the left side.
The right side of the vehicle uses a longer solid interconnecting shaft.
The left driveshaft uses a tuned rubber damper weight, which is a double clamp style damper.
When replacing the left driveshaft, be sure the replacement driveshaft has the same damper weight
as the original.
Both driveshaft assemblies use the same type of inner and outer joints. The inner joint of both
driveshaft assemblies is a tripod joint, and the outer joint of both driveshaft assemblies is a Rzeppa
joint. Both tripod joints and Rzeppa joints are true Constant Velocity (C/V) joint assemblies. The
inner tripod joint allows for the changes in driveshaft length through the jounce and rebound travel
of the front suspension.
On vehicles equipped with ABS brakes, the outer C/V joint is equipped with a tone wheel used to
determine vehicle speed for ABS brake operation.
The inner tripod joint of both driveshafts is splined into the transaxle side gears. The inner tripod
joints are retained in the side gears of the transaxle using a snap ring located in the stub shaft of
the tripod joint. The outer C/V joint has a stub shaft that is splined into the wheel hub and retained
by a hub nut using a nut lock and cotter pin, hub nut retention system.
NOTE: This vehicle does not use a rubber lip bearing seal as on past front wheel drive cars, to
prevent contamination of the front wheel bearing. On these vehicles, the face of the outer CV joint
has a metal bearing shield which is pressed onto the end of the outer CV joint housing. This design
deters direct water splash on bearing seal while allowing any water that gets in, to run out the
bottom of the bearing shield. It is important though to thoroughly clean the outer CV joint and the
wheel bearing area in the steering knuckle before it is assembled after servicing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Description and Operation > Page 3822
Axle Shaft: Testing and Inspection
VEHICLE INSPECTION
1. Check for grease in the vicinity of the inboard tripod joint and outboard C/V joint; this is a sign of
inner or outer joint seal boot or seal boot clamp
damage.
2. A light film of grease may appear on the right inner tripod joint seal boot; this is considered
normal and should not require replacement of the seal
boot.
NOISE AND/OR VIBRATION IN TURNS
A clicking noise and/or a vibration in turns could be caused by one of the following conditions: 1.
Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss
and/or contamination of the joint grease,
resulting in inadequate lubrication of the joint.
2. Noise may also be caused by another component of the vehicle coming in contact with the
driveshafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of one of the following conditions: 1. A torn seal boot on the inner or
outer joint of the driveshaft assembly. 2. A loose or missing clamp on the inner or outer joint of the
driveshaft assembly. 3. A damaged or worn driveshaft C/V joint.
SHUDDER OR VIBRATION DURING ACCELERATION
This problem could be a result of: 1. A worn or damaged driveshaft inner tripod joint. 2. A sticking
tripod joint spider assembly (inner tripod joint only). 3. Improper wheel alignment. See Wheel
Alignment specifications.
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of: 1. Foreign material (mud, etc.) packed on the backside of the
wheel(s). 2. Out of balance front tires or wheels. 3. Improper tire and/or wheel runout.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation
Axle Shaft: Service and Repair Removal and Installation
REMOVAL
CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing
assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a
PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 Nm (180 ft. lbs.).
This will ensure that the hub bearing cannot loosen.
Fig. 1
1. Remove cotter pin, nut lock, and spring washer from the end of the outer C/V joint stub axle.
Fig. 2
2. Loosen (but do not remove) stub axle to hub/bearing retaining nut. Loosen hub nut while vehicle
is on the floor with the brakes applied. The front
hub and driveshaft are splined together and retained by the hub nut.
3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Remove front tire and
wheel assembly from the hub.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation > Page 3825
Fig. 3
5. Remove front disc brake caliper assembly to steering knuckle guide pin attaching bolts.
Fig. 4
6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting
bottom of caliper away from steering knuckle, and
then removing top of caliper out from under steering knuckle.
Fig. 5
7. Support brake caliper/adapter assembly using a wire hook. Do not support assembly by the
brake flex hose. 8. Remove braking disc from front hub.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation > Page 3826
Fig. 6
9. Remove nut attaching outer tie rod end to steering knuckle. Remove nut from tie rod end by
holding tie rod end stud with a 11/32 socket and
loosen and remove nut.
Fig. 7
10. Remove the tie rod end stud from steering knuckle arm, using remover, Special Tool
MB-990635.
Fig. 8
11. If equipped with antilock brakes, remove the speed sensor cable routing bracket from the
steering knuckle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation > Page 3827
Fig. 9
12. Remove cotter pin and castle nut from stud of lower ball joint at the steering knuckle.
CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to
separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated
from the stud of the ball joint only using the procedure as described in Step 13.
Fig. 10
13. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel
well as possible. Using a hammer strike steering
knuckle boss until steering knuckle separates from stud of lower ball joint. When striking steering
knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal.
NOTE: Care must be taken not to separate the inner ON joint during this operation. Do not allow
driveshaft to hang by inner ON joint. Driveshaft must be supported.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation > Page 3828
Fig. 11
14. Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft assembly.
CAUTION: When inserting pry bar between inner tripod joint and transaxle case, care must be
used to ensure no damage occurs to oil seal in transaxle case.
Fig. 12
15. Support the outer end of the driveshaft assembly. Insert a pry bar between inner tripod joint and
transaxle case. Pry against inner tripod joint, until
tripod joint retaining snap ring is disengaged from transaxle side gear.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation > Page 3829
Fig. 13
16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod
joint from transaxle, by pulling it straight out of
transaxle side gear and transaxle oil seal. When removing tripod joint, do not let spline or snap ring
drag across sealing lip of the transaxle to tripod joint oil seal.
CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing
assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a
PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 Nm (180 ft. lbs.).
This will ensure that the hub bearing cannot loosen.
INSTALLATION
1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean
transmission lubricant.
2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into
transaxle side gear as far as possible by hand. 3. Grasp inner tripod joint an interconnecting shaft.
Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with
transaxle side gear. Test that snap ring is fully engaged with side gear by attempting to remove
tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not
be removable by hand.
4. Clean all debris and moisture out of steering knuckle, in the area were outer C/V joint will be
installed into steering knuckle.
Fig. 14
5. Ensure that front of outer C/V joint which fits against the face of the hub and bearing is free of
debris and moisture before installing outer C/V
joint into hub and bearing assembly.
Fig. 15
6. Slide driveshaft back into front hub. Then install steering knuckle onto the lower control arm ball
joint stud.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation > Page 3830
Fig. 16
7. Install the steering knuckle to ball joint stud castle nut. Tighten the castle nut to 95 Nm (70 ft.
lbs.).
Fig. 17
8. If equipped with antilock brakes, install the speed sensor cable on the steering knuckle and
securely tighten bolt.
Fig. 18
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation > Page 3831
Fig. 19
9. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle nut onto stud of
tie rod end. While holding stud of tie rod end
stationary , tighten tie rod end to steering knuckle nut. Using a crowfoot and 11/32 socket, tighten
the nut to 61 Nm (45 ft. lbs.).
10. Install braking disc back on hub and bearing assembly.
Fig. 20
11. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of
caliper under top abutment on steering knuckle.
Then installing bottom of caliper against bottom abutment of steering knuckle.
Fig. 21
12. Install caliper assembly to steering knuckle guide pin bolts. Tighten caliper assembly bolts to 31
Nm (23 ft. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation > Page 3832
Fig. 22
13. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto
threads of stub axle and tighten nut.
Fig. 23
14. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 244 Nm (180
ft. lbs.).
Fig. 24
15. Install the spring washer, hub nut lock, and new cotter pin on end of stub axle. Wrap cotter pin
prongs tightly around the hub nut lock.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation > Page 3833
Fig. 25
16. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in the correct
sequence. Tighten lug nuts to 135 Nm (100 ft. lbs.). 17. Lower vehicle. 18. Check for correct fluid
level in transaxle assembly. Refer to Transmission and Drivetrain for the correct fluid level checking
procedure for the type
of transaxle being checked.
19. Set front toe on vehicle to required specification.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal and Installation > Page 3834
Axle Shaft: Service and Repair Disassembly and Assembly
CAUTION: The outer C/V joint used on this vehicle uses a new design for retaining the cross to the
interconnecting shaft. These driveshafts incorporate a slight twist (helical) in the spline on the
interconnecting shaft where the cross is installed. This twist causes a interference fit between the
interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting
shaft. This design eliminates the clearance between the cross and the interconnecting shaft
resulting in quieter operation of the driveshaft assembly. This design though eliminated the
capability of removing the outer C/V joint from the interconnecting shaft. For this reason the
driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft
and vibration damper) in the event of a outer C/V joint boot failure.
NOTE: The only service which is to be performed on the driveshaft assemblies is the replacement
of the driveshaft seal boots on the inner tripod joints.
If any failure of internal driveshaft components is diagnosed during a vehicle road test or
disassembly of the driveshaft, the driveshaft will need to be replaced as an assembly.
CAUTION: Lubricant requirements and quantities are different for inner joints than for outer joints.
Use only the recommended lubricants in the required quantities when servicing driveshaft
assemblies.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair
Constant Velocity Joint: Service and Repair
OVERVIEW
The front hub/bearing shield on the outer C/V joint is a serviceable component of the outer C/V. If it
is damaged in use on a vehicle or during servicing of a driveshaft it can be replaced using the
following procedure. To remove the bearing shield from the outer C/V joint, the driveshaft
assemblies must be removed from the vehicle.
BEARING SHIELD REMOVAL FROM OUTER CV JOINT
1. Clamp driveshaft in a vise by the interconnecting shaft.
Fig. 49
2. Using a drift tap around the entire edge of the bearing shield until it is removed from.
BEARING SHIELD INSTALLATION ON OUTER C/V JOINT
1. Install bearing shield by hand on outer C/V Joint so that it is installed squarely on the C/V joint.
Fig. 50
2. Position installer, Special Tool, C-4698-2 and handle, Special Tool, C-4698-1 on face of bearing
shield.
CAUTION: If bearing shield is not installed flush against the face of the outer C/V joint, interference
with steering knuckle will occur when driveshaft is installed.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint > Component Information > Service and Repair > Page 3838
Fig. 51
3. Using a hammer, drive the bearing shield on the outer C/V joint until it is flush against the front of
the outer C/V joint.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > CV Boot - Grease Seepage
Explanation
Constant Velocity Joint Boot: Technical Service Bulletins CV Boot - Grease Seepage Explanation
NO: 03-06-98
GROUP: Differential & Drive Line
DATE: Oct. 2, 1998
SUBJECT: CV Boot Grease Seepage
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
DISCUSSION:
The right side half shaft inner CV joint boot on subject vehicles is made of a special high
temperature resistant material that can show heavy grease seepage - enough to form droplets on
the boot convolutes. Although the seepage is unsightly and will stop eventually, it does not affect
function or durability.
No replacement of the half shaft or boot is necessary for this condition. The boot should be wiped
clean as necessary.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot
Constant Velocity Joint Boot: Service and Repair Inner Tripod Joint Sealing Boot
REMOVAL
To remove sealing boots from driveshafts, the driveshaft assemblies must be removed from the
vehicle. The inner tripod joints use no internal retention in the tripod housing to keep the spider
assembly in the housing. Therefore, do not pull on the interconnecting shaft to disengage tripod
housing from transmission stub shaft. Removal in this manner will cause damage to the inboard
joint sealing boots. 1. Remove the driveshaft requiring boot replacement from the vehicle. 2.
Remove large boot clamp which retains inner tripod joint sealing boot to tripod joint housing and
discard. Remove small clamp which retains inner
tripod joint sealing boot to interconnecting shaft and discard. Remove the sealing boot from the
tripod housing and slide it down the interconnecting shaft.
CAUTION: When removing the tripod joint housing from the spider assembly' hold the bearings in
place on the spider bunions to prevent the bearings from falling away.
Fig. 26
3. Slide the tripod joint housing off the spider assembly and the interconnecting shaft.
Fig. 27
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3845
Fig. 28
4. Remove snap ring which retains spider assembly to interconnecting shaft. Remove the spider
assembly from interconnecting shaft. If spider
assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider
assembly with a brass drift. Do not hit the outer tripod bearings in an attempt to remove spider from
interconnecting. shaft.
5. Slide sealing boot off interconnecting shaft. 6. Thoroughly clean and inspect spider assembly,
tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show
signs of excessive wear, the driveshaft assembly will require replacement. Component parts of
these driveshaft assemblies are not serviceable.
INSTALLATION
NOTE: The inner tripod joint sealing boots are made from two different types of material. High
temperature applications use silicone rubber where as standard temperature applications use
hytrel plastic. The silicone sealing boots are soft and pliable. The Hytrel sealing boots are stiff and
rigid. The replacement sealing boot MUST BE the same type of material as the sealing boot which
was removed.
Fig. 29
1. Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then, slide the
replacement inner tripod joint sealing boot onto the
interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so
the raised bead on the inside of the seal boot is in groove on interconnecting shaft.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3846
Fig. 30
Fig. 31
2. Install spider assembly onto interconnecting shaft. Spider assembly must be installed on
interconnecting shaft far enough to fully install spider
retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can
be installed by tapping the spider body with a brass drift. Do not hit the outer tripod bearings in an
attempt to install spider assembly on interconnecting shaft.
Fig. 32
3. Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of
interconnecting shaft. Be sure the snap ring is fully
seated into Groove on interconnecting shaft.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3847
4. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE
ANY OTHER TYPE OF GREASE) into tripod
housing. Put the remaining amount into the sealing boot.
Fig. 33
5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly
and interconnecting shaft. 6. Install inner tripod joint seal boot to interconnecting shaft clamp evenly
on sealing boot.
Fig. 34
Fig. 35
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3848
7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the
following procedure. Place crimping tool C-4975-A
over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed
completely together, face to face.
CAUTION: Seal must not be dimpled, stretched or out of shape in any way. If seal is NOT shaped
correctly, equalize pressure in seal and shape it by hand.
8. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp
evenly on sealing boot.
CAUTION: The following positioning procedure determines the correct air pressure inside the inner
tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this
procedure is not done prior to clamping sealing boot to tripod joint housing sealing boot durability
can be adversely affected.
CAUTION: When venting the inner tripod joint assembly, use care so inner tripod sealing boot does
not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any
way while being vented, the sealing boot can not be used.
Fig. 36
9. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint
assembly. When inserting trim stick between tripod
housing and sealing boot ensure trim stick is held flat and firmly against the tripod housing If this is
not done damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard plastic)
sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing not the
hard plastic sealing boot and soft rubber
10. With trim stick inserted between sealing boot and tripod joint housing, position the
interconnecting shaft so it is at the center of its travel in the
tripod joint housing. Remove the trim stick from between the sealing boot and the tripod joint
housing. This procedure will equalize the air pressure in the tripod joint, preventing premature
sealing boot failure.
11. Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly
aligned with the recess's of the tripod housing. 12. Clamp tripod joint sealing boot to tripod joint,
using required procedure for type of boot clamp application.
CRIMP TYPE BOOT CLAMP If seal boot uses crimp type boot clamp: Clamp sealing boot onto tripod housing using Crimper, Special Tool C-4975-A.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3849
Fig. 37
- Place crimping tool C-4975-A over bridge of clamp.
Fig. 38
- Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to
face.
LATCHING TYPE BOOT CLAMP If seal boot uses low profile latching type boot clamp: Clamp sealing boot onto tripod housing using clamp locking tool, Snap-On YA3050 or an
equivalent.
Fig. 39
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3850
- Place prongs of clamp locking tool in the holes of the clamp.
Fig. 40
- Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of
clamp.
13. Install the driveshaft back on the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3851
Constant Velocity Joint Boot: Service and Repair Outer C/V Joint Sealing Boot
REMOVAL
To remove outer C/V joint sealing boot from a driveshaft for replacement, the driveshaft assembly
must be removed from the vehicle. See Driveshaft Removal and Installation for the required
driveshaft removal and replacement procedure. 1. Remove driveshaft assembly requiring boot
replacement from vehicle.
Fig. 41
2. Remove large boot clamp retaining C/V joint sealing boot to C/V joint housing and discard.
Remove small clamp that retains outer C/V joint
sealing boot to interconnecting shaft and discard. Remove sealing boot from outer C/V joint
housing and slide it down interconnecting shaft.
Fig. 42
3. Wipe away grease to expose outer C/V joint to interconnecting shaft retaining ring. Spread ears
apart on C/V joint assembly to interconnecting
shaft retaining snap ring. Slide outer C/V joint assembly off end of interconnecting shaft.
4. Slide failed sealing boot off interconnecting shaft. 5. Thoroughly clean and inspect outer C/V joint
assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of
excessive wear, the driveshaft assembly will require replacement. Component parts of these
driveshaft assemblies are not serviceable.
INSTALLATION
1. Slide a new seal boot to interconnecting shaft retaining clamp, onto the interconnecting shaft.
Then slide the replacement outer C/V joint assembly
sealing boot onto the interconnecting shaft.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3852
Fig. 43
2. Install outer C/V joint assembly onto interconnecting shaft. Joint is installed on interconnecting
shaft, by pushing interconnecting shaft into outer
C/V joint, until retaining snap ring is seated in groove on interconnecting shaft. Verify the snap ring
is fully seated into groove on interconnecting shaft.
3. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY
OTHER TYPE OF GREASE) into outer C/V joint
assembly housing. Put the remaining amount into the sealing boot.
Fig. 44
4. Install outer C/V joint seal boot retaining clamp, onto interconnecting shaft. Install replacement
outer C/V joint sealing boot onto interconnecting
shaft. Outer C/V joint seal boot MUST be positioned on interconnecting shaft, so only the thinnest
(sight) groove on interconnecting shaft is visible.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3853
Fig. 45
Fig. 46
5. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the
following procedure. Place crimping tool C-4975-A
over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed
completely together, face to face.
CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped
correctly, equalize pressure in seal and shape it by hand.
6. Position outer C/V joint sealing boot into its retaining groove on outer C/V joint housing. Install
sealing boot to outer C/V joint retaining clamp
evenly on sealing boot.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Sealing Boot > Page 3854
Fig. 47
Fig. 48
7. Clamp sealing boot onto outer C/V joint housing using Crimper, Special Tool C-4975-A and the
following procedure. Place crimping tool
C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed
completely together, face to face.
8. Install the driveshaft requiring boot replacement back on the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Specifications
Wheel Bearing: Specifications Lubricant Type
Lubricant Type
Wheel Bearing Grease NLGI GC rated automotive grease
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
FRONT:
To Hub Bearing Nut .............................................................................................................................
............................................ 183 Nm (135 ft. lbs.)
REAR:
Stub Axle Nut .......................................................................................................................................
............................................ 224 Nm (180 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
TORQUE SPECIFICATIONS
Drive Plate-to-Crankshaft Bolts ...........................................................................................................
..................................................... 95 Nm (70 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Specifications
Control Module: Specifications
Sixty-Way Connector 35 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Specifications > Page 3870
Transmission Control Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Connector Pin Identification
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Control Module: Description and Operation
AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT
The electronic automatic transaxle control module and the PCM supply information to each other
through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the
information when adjusting the fuel and ignition strategy.
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Control Module: Service and Repair
OVERVIEW
Do not interchange Transmission Control Modules with previous year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed: Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
REMOVAL
Fig. 27
1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then
disconnect the 60 way connector on Transmission
Control Module.
Fig. 28
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Fig. 29
2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28
and 29).
INSTALLATION
1. To install, reverse removal procedure.
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Transmission Control System Relay: Locations
Battery Negative Cable
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Power Distribution Center -- Sheet 8w-10-2
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Transmission Control System Relay: Diagrams
Power Distribution Center
Transmission Control Relay (EATX)
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Transmission Control System Relay: Description and Operation
TRANSMISSION CONTROL RELAY
The transmission control relay is located in the Power Distribution Center (PDC) on the left side of
the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is
used to supply power to the solenoid pack when the transmission is in normal operating mode.
When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in
mode. After a controller reset (ignition key turned to the run position or after cranking engine), the
TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for
no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack
pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify
that the voltage is greater than 3 volts.
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Autostick/Overdrive Off
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3906
Autostick/Overdrive Switch Connector Pin Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations
Transmission Mode Switch: Locations
For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Locations > Page 3910
Transmission Mode Switch: Diagrams
For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Transmission Range Sensor - Production Change > Page 3915
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Transmission Range Sensor - Production Change > Page 3916
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Page 3917
Transmission Range Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Page 3918
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Page 3919
Transmission Position Switch/Sensor: Description and Operation
Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical
TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT
The park/neutral switch is located on the transaxle housing.
If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral.
This input is used to determine idle speed (varying with gear selection) and ignition timing advance.
The park neutral switch is sometimes referred to as the neutral safety switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Page 3920
Transmission Position Switch/Sensor: Service and Repair
The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
Fig. 20
3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission
range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8.
Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
Fig. 21
11. Place valve body on workbench (Fig. 21).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Page 3921
Fig. 22
12. Remove TRS retaining screw (Fig. 22).
Fig. 23
13. Remove manual shaft seal (Fig. 23).
Fig. 24
14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24).
INSTALLATION
1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.)
Reseal transaxle oil pan using RTV.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control >
Page 3930
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of
Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of
Cruise Control > Page 3936
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3937
Transmission Speed Sensor: Specifications
Speed Sensor Input 20 ft.lb
Output 20 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 3938
Input Speed Sensor/Output Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor > Page
3941
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor
Transmission Speed Sensor: Service and Repair Input Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 25
The input speed sensor is located to the left of the manual shift lever (Fig. 25).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Input Sensor >
Page 3944
Transmission Speed Sensor: Service and Repair Output Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 26
The output speed sensor is located to the right of the manual shift lever (Fig. 26).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Power Transfer Unit .............................................................................................................................
........................................................ 1.2L (2.4 Pints)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Specifications > Capacity Specifications > Page 3950
Fluid - Transfer Case: Fluid Type Specifications
Power Transfer Unit
Viscosity ..............................................................................................................................................
.............................................................. SAE 85W-90
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Specifications > Page 3951
Fluid - Transfer Case: Service Precautions
DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
A604 (41TE) 4 Speed Transaxle
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications
Control Module: Specifications
Sixty-Way Connector 35 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Specifications >
Page 3963
Transmission Control Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3966
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3967
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3968
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3969
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3970
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Diagram Information and Instructions > Page 3972
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Diagram Information and Instructions > Page 3973
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Diagram Information and Instructions > Page 3974
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diagram Information and Instructions > Page 3975
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Diagram Information and Instructions > Page 3976
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Diagram Information and Instructions > Page 3978
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Diagram Information and Instructions > Page 3979
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Diagram Information and Instructions > Page 3980
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Diagram Information and Instructions > Page 3981
Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Diagram Information and Instructions > Page 3982
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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Diagram Information and Instructions > Page 3983
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Diagram Information and Instructions > Page 3984
Connector Pin Identification
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Page 3985
Control Module: Description and Operation
AUTOMATIC TRANSAXLE CONTROL MODULE-PCM OUTPUT
The electronic automatic transaxle control module and the PCM supply information to each other
through the CCD Bus. The information includes engine speed and vehicle load. The PCM uses the
information when adjusting the fuel and ignition strategy.
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Page 3986
Control Module: Service and Repair
OVERVIEW
Do not interchange Transmission Control Modules with previous year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed: Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
REMOVAL
Fig. 27
1. Loosen 60 way retaining screw, located in the center of the 60 way connector (Fig.27). Then
disconnect the 60 way connector on Transmission
Control Module.
Fig. 28
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Fig. 29
2. Remove Transmission Control Module mounting screws and lift module from vehicle (Figs 28
and 29).
INSTALLATION
1. To install, reverse removal procedure.
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Information > Locations
Transmission Control System Relay: Locations
Battery Negative Cable
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Information > Locations > Page 3991
Power Distribution Center -- Sheet 8w-10-2
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Information > Locations > Page 3992
Transmission Control System Relay: Diagrams
Power Distribution Center
Transmission Control Relay (EATX)
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Transmission Control System Relay: Description and Operation
TRANSMISSION CONTROL RELAY
The transmission control relay is located in the Power Distribution Center (PDC) on the left side of
the engine compartment. The relay is supplied fused B+ voltage, energized by the TCM, and is
used to supply power to the solenoid pack when the transmission is in normal operating mode.
When the relay is off, no power is supplied to the solenoid pack and the transmission is in limp-in
mode. After a controller reset (ignition key turned to the run position or after cranking engine), the
TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for
no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack
pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify
that the voltage is greater than 3 volts.
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Autostick/Overdrive Off
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Page 3999
Autostick/Overdrive Switch Connector Pin Locations
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Locations
Transmission Mode Switch: Locations
For component location, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
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Locations > Page 4003
Transmission Mode Switch: Diagrams
For connector pin locations, refer to Automatic Transmission/Transaxle, Overdrive Switch Transmission.
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Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
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Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 4008
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Transmission Range Sensor - Production Change > Page 4009
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Page 4010
Transmission Range Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Page 4011
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Page 4012
Transmission Position Switch/Sensor: Description and Operation
Park Neutral Switch-4 Speed Electronic Automatic Transaxle-Typical
TRANSAXLE PARK/NEUTRAL SWITCH-PCM INPUT
The park/neutral switch is located on the transaxle housing.
If provides an input to the PCM indicating whether the automatic transaxle is in Park or Neutral.
This input is used to determine idle speed (varying with gear selection) and ignition timing advance.
The park neutral switch is sometimes referred to as the neutral safety switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Page 4013
Transmission Position Switch/Sensor: Service and Repair
The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil
pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
Fig. 20
3. Remove gearshift cable (Fig. 20). 4. Remove manual valve lever. 5. Disconnect transmission
range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8.
Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
Fig. 21
11. Place valve body on workbench (Fig. 21).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Page 4014
Fig. 22
12. Remove TRS retaining screw (Fig. 22).
Fig. 23
13. Remove manual shaft seal (Fig. 23).
Fig. 24
14. Slide Transmission Range Sensor up the manual shaft and remove (Fig. 24).
INSTALLATION
1. For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.)
Reseal transaxle oil pan using RTV.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 4023
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control > Page 4029
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Page 4030
Transmission Speed Sensor: Specifications
Speed Sensor Input 20 ft.lb
Output 20 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Page 4031
Input Speed Sensor/Output Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Input Speed Sensor
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Input Speed Sensor > Page 4034
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Input Sensor
Transmission Speed Sensor: Service and Repair Input Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 25
The input speed sensor is located to the left of the manual shift lever (Fig. 25).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Input Sensor > Page 4037
Transmission Speed Sensor: Service and Repair Output Sensor
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Fig. 26
The output speed sensor is located to the right of the manual shift lever (Fig. 26).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Description and Operation
ABS Light: Description and Operation
The amber ABS warning lamp is located on the right side of the message center located at the top
of the instrument panel.
When the ignition key is turned to the ON position, the amber ABS warning lamp is lit until the CAB
completes its self-tests and turns off the lamp (approximately 4 seconds). The amber ABS warning
lamp will illuminate when the CAB detects a condition that results in the shutdown of ABS function,
or when the body controller does not receive a CCD message from the CAB. The CAB turns on the
amber ABS warning lamp by grounding the circuit.
Under most conditions, when the amber ABS warning lamp is on, only the ABS function of the
brake system is affected; the base brake system and the ability to stop the vehicle are not affected.
The amber ABS warning lamp is controlled by the CAB and the body controller through a diode
located in the junction block. The CAB and body controller control the amber ABS warning lamp by
directly grounding the circuit.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Description and Operation > Page 4043
ABS Light: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay >
Component Information > Description and Operation
ABS Main Relay: Description and Operation
ABS FUSES
The ABS system fuse and the ABS pump/motor fuse are located in the Power Distribution Center
(PDC). Refer to the sticker on the inside of the PDC cover for the location of these fuses. The PDC
is located on the driver's side of the engine compartment. The fuse for the amber ABS warning
lamp is located in the fuse junction block under the instrument panel.
If the vehicle is equipped with traction control, the fuse for the traction control switch is located in
the fuse junction block under the instrument panel.
ABS RELAYS
Two relays are used to control the antilock brake system. The two relays are the pump/motor relay
and the system relay. The pump/motor relay and the system relay are located in the CAB. If either
the pump/motor relay or the system relay is diagnosed as not functioning properly, the CAB must
be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump
> Component Information > Locations
Hydraulic Control Unit
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump
> Component Information > Locations > Page 4050
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications
Electronic Brake Control Module: Specifications
To HCU Mounting Bolts .......................................................................................................................
.................................................. 2 Nm (17 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 4054
Controller Antilock Brake (CAB)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 4055
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 4056
Electronic Brake Control Module: Description and Operation
The Controller Antilock Brake (CAB) is a microprocessor-based device which monitors the ABS
system during normal braking and controls it when the vehicle is in an ABS stop. The CAB is
mounted to the bottom of the HCU. The CAB uses a 25-way electrical connector on the vehicle
wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON
position. The CAB is on the CCD bus.
The primary functions of the (CAB) are to: 1. monitor the antilock brake system for proper
operation. 2. detect wheel locking or wheel slipping tendencies by monitoring the speed of all four
wheels of the vehicle. 3. control fluid modulation to the wheel brakes while the system is in an ABS
mode or the traction control system is activated. 4. store diagnostic information. 5. provide
communication to the DRB scan tool while in diagnostic mode.
The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a
fault, it will turn on the amber ABS warning lamp and disable the antilock braking system. The
normal base braking system will remain operational.
The CAB continuously monitors the speed of each wheel through the signals generated by the
wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking
tendency is detected, the CAB commands the CAB command coils to actuate. The CAB command
coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all
of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until
a locking tendency is no longer present.
The CAB contains a self-diagnostic program that monitors the antilock brake system for system
faults. When a fault is detected, the amber ABS warning lamp is turned on and the fault Diagnostic
Trouble Code (DTC) is then stored in a diagnostic program memory. These DTCs will remain in the
CAB memory even after the ignition has been turned off. The DTCs can be read and cleared from
the CAB memory by a technician using the DRB scan tool. If not cleared with a DRB scan tool, the
fault occurrence and DTC will be automatically cleared from the CAB memory after the identical
fault has not been seen during the next 255 key cycles of vehicle operation or 3,600 miles,
whichever comes first.
CONTROLLER ANTILOCK BRAKE INPUTS
- wheel speed sensors (four)
- stop lamp switch
- ignition switch
- system relay voltage
- ground.
- traction control lamp (if equipped)
- diagnostic communication (CCD)
CONTROLLER ANTILOCK BRAKE OUTPUTS
- body controller communication
- amber ABS warning lamp actuation
- traction control lamp (if equipped)
- diagnostic communication (CCD)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Mounting Bracket To Suspension Cradle Bolts
.................................................................................................................................. 28 Nm (250 inch
lbs.) To Mounting Bracket Isolator Attaching Bolts
..................................................................................................................................... 11 Nm (97
inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 4060
Hydraulic Control Unit
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 4061
Hydraulic Control Assembly - Antilock Brakes: Description and Operation
Teves Mark 20 ICU
The Hydraulic Control Unit (HCU) is mounted to the CAB as part of the ICU. The ICU is located on
the driver's side of the front suspension cradle under the vehicle. The HCU controls the flow of
brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on
the HCU to supply build pressure to the brakes during an ABS stop.
The HCU on a vehicle equipped with ABS and traction control has a valve block housing that is
approximately 1 inch longer on the low pressure fluid accumulators side than a HCU on a vehicle
that is equipped with only ABS.
VALVES AND SOLENOIDS
The valve block contains four inlet valves and four outlet valves. The inlet valves are spring-loaded
in the open position and the outlet valves are spring loaded in the closed position during normal
braking. The fluid is allowed to flow from the master cylinder to the wheel brakes.
During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet
valve closes preventing further pressure increase and the outlet valve opens to provide a path from
the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from
the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer
slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure.
On vehicles with traction control, there is an extra set of valves and solenoids. The ASR valves,
mounted in the HCU valve block, are normally in the open position and close only when the traction
control is applied.
These isolator valves are used to isolate the rear (non-driving) wheels of the vehicle from the
hydraulic pressure that the HCU pump/motor is sending to the front (driving) wheels when traction
control is being applied. The rear brakes need to be isolated from the master cylinder when traction
control is being applied so the rear wheels do not drag. For more information, see Traction Control
System.
BRAKE FLUID ACCUMULATORS
There are two fluid accumulators in the HCU-one for the primary hydraulic circuit and one for the
secondary hydraulic circuit. Each hydraulic circuit uses a 5 cc accumulator.
The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during
an ABS cycle. This stored fluid is used by the pump/motor to provide build pressure for the brake
hydraulic system. When the antilock stop is complete, the accumulators are drained by the
pump/motor.
On ABS-only vehicles, there is a mini-accumulator on the secondary hydraulic circuit that protects
the master cylinder seals during an ABS stop, and there is a noise dampening chamber on the
primary circuit.
On ABS with traction control vehicles, there are two noise dampening chambers in the HCU.
PUMP/MOTOR
There are two pump assemblies in the HCU-one for the primary hydraulic circuit and one for the
secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type
motor is integral to the HCU and is controlled by the CAB.
The pump/motor provides the extra amount of brake fluid needed during antilock braking. Brake
fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The
pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In
operation, one piston draws fluid from the accumulators, and the opposing piston pumps fluid to the
master cylinder circuits. When the antilock stop is complete, the pump/motor drains the
accumulators.
The CAB may turn on the pump/motor when an antilock stop is detected. The pump/motor
continues to run during the antilock stop and is turned off
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 4062
after the stop is complete. Under some conditions, the pump/motor runs to drain the accumulators
during the next drive-off.
The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU)
Replacement
Removal
NOTE: Before proceeding, review all SERVICE WARNINGS AND CAUTIONS in Service
Precautions.
1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake
pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This
will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the HCU.
3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type
hoist.
CAB 25 Way Connector
4. Remove the routing clip attaching the ICU wiring harness to the ICU mounting bracket.
CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector
when disconnected.
Unlocked 25 Way CAB Connector
5. Remove the 25 way connector from the CAB. The 25 way connector is removed from the CAB
using the following procedure. Grasp the lock on
the 25 way connector and pull it as far out as possible. This will raise and unlock the 25 way
connector from the socket on the CAB.
CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned.
This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake
tubes.
6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only
a solvent such as Mopar Brake Parts Cleaner or
an equivalent to clean the HCU.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement >
Page 4065
Brake Tube Connections To HCU
7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU.
ICU To Suspension Cradle Mounting Bolts
8. Remove the 3 bolts attaching the ICU mounting bracket to the front suspension crossmember. 9.
Remove ICU and the mounting bracket as a unit from the vehicle.
ICU Mounting Bolts
10. Remove the 3 bolts mounting the ICU to the mounting bracket. Separate the ICU from the
mounting bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement >
Page 4066
11. Refer to Overhaul for the procedure on separating and attaching the CAB to the HCU.
Installation
1. Install the ICU on the mounting bracket. Install the 3 bolts attaching the ICU to the mounting
bracket. Tighten the 3 mounting bolts to a torque of
11 Nm (97 inch lbs.).
CAUTION: The ICU mounting bracket to front suspension cradle mounting bolts have a unique
corrosion protection coating and a special aluminum washer. For this reason, only the original, or
original equipment Mopar replacement bolts can be used to mount the ICU bracket to the front
suspension crossmember.
2. Install the ICU and its mounting bracket as an assembly on the front suspension crossmember.
Install the 3 bolts attaching the ICU bracket to the
crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.).
Brake Tube Connections To HCU
CAUTION: ^
Because of the flexible section in the primary and secondary brake tubes, and the brake tubes
between the HCU and the proportioning valve, the brake tubes must be held in proper orientation
when tightened and torqued. These tubes must not contact each other or other vehicle components
when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are
reinstalled on the brake tubes.
^ When installing the chassis brake tubes on the HCU valve block, they must be located correctly
in the valve block to ensure proper ABS operation. Refer to the image for the correct chassis brake
tube locations.
NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the
ICU mounting bracket.
3. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as
shown. Tighten the tube nuts to a torque of 17 Nm
(145 inch lbs.).
NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in
the connector.
4. Install the 25 way connector on the CAB using the following procedure. Position the 25 way
connector in the socket of the CAB and carefully
push it down as far as possible. When connector is fully seated by hand into the CAB socket, push
in the connector lock. This will pull the connector into the socket of the CAB and lock it in the
installed position.
NOTE: The CAB wiring harness must be clipped to the ICU mounting bracket. This will ensure the
wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle.
5. Clip the cab wiring harness to the ICU mounting bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement >
Page 4067
Brake Tube Routing Clips
6. Install the routing clips on the brake tubes. 7. Lower the vehicle. 8. Connect negative cable back
on negative post of the battery. 9. Bleed the base and ABS hydraulic systems.
10. Road test vehicle to ensure proper operation of the base and antilock brake systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement >
Page 4068
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU)
Overhaul
REMOVAL
NOTE: To replace the Hydraulic Control Unit (HCU) or the Controller Antilock Brake (CAB) on this
vehicle, the entire Integrated Control Unit (ICU) needs to be removed from the vehicle. The CAB
can then be separated from the HCU. Do not attempt to replace the CAB with the ICU mounted in
the vehicle.
1. Remove the ICU from the vehicle.
Pump/Motor To CAB Wiring Harness
2. Disconnect the pump/motor wiring harness from the CAB.
CAB Attaching Bolts
3. Remove the 4 bolts attaching the CAB to the HCU.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement >
Page 4069
Remove/Install CAB
4. Remove the CAB from the HCU.
INSTALLATION
1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB
mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the
CAB. 4. Install the ICU in the vehicle. 5. Bleed the base and ABS hydraulic systems. 6. Road test
the vehicle to ensure proper operation of the base brakes and ABS.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Indicator Lamp > Component Information > Testing and Inspection
Traction Control Indicator Lamp: Testing and Inspection
The traction control light is tested by cycling the traction control switch on and off. The traction
control switch used on this vehicle is a momentary contact type switch. The test procedure for the
traction control light is performed as follows: Press the traction control switch once and the TRAC
OFF lamp will illuminate. With the TRAC OFF lamp illuminated, press the traction control switch
again and the TRAC OFF lamp will turn off.
If the traction control lamp does not function as described in the test above, diagnosis of the
traction control switch, lamp, wiring and other related components of the traction control system is
required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations
Traction Control Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Diagrams > Harness Side
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Diagrams > Harness Side > Page 4078
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Diagrams > Page 4079
Traction Control Switch: Testing and Inspection
Traction Control Switch Connector
1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading
between pins.
Traction Control Switch Continuity
Switch Position = Continuity between Actuated = Pins 1 and 2 Illumination = Pins 1 and 3
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Diagrams > Page 4080
Traction Control Switch: Service and Repair
Battery Negative Cable
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the over steering column bezel. 3.
Remove the two screws attaching traction control switch to the bezel.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications
Wheel Speed Sensor: Electrical Specifications
Allowable Resistance 900 - 1300 ohms
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications > Page 4085
Wheel Speed Sensor: Mechanical Specifications
Front Rear
Minimum Clearance 0.014 in 0.016 in
Maximum Clearance 0.047 in 0.047 in
To Axle Or Steering Knuckle Mounting Bolt 105 in.lb 105 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Front Wheel Speed Sensors
Front Wheel Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 4088
Rear Wheel Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Front
Wheel Speed Sensor: Diagrams Front
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Front > Page 4091
Wheel Speed Sensor: Diagrams Rear
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Page 4092
Wheel Speed Sensor: Description and Operation
Front Wheel Speed Sensor
Rear Wheel Speed Sensor (FWD)
One Wheel Speed Sensor (WSS) and one tone wheel are located at each front and rear wheel.
Each front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel
is part of the outboard constant velocity joint. The rear wheel speed sensor on rear disc brake
applications is mounted to the rear disc brake adapter. The rear tone wheel is an integral part of
the rear wheel hub and bearing.
The wheel speed sensor sends a small AC signal to the CAB. This signal is generated by magnetic
induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic wheel
speed sensor. The CAB converts the AC signal into a digital signal. If a wheel locking tendency is
detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s)
from locking.
Correct ABS operation is dependent on accurate wheel speed signals. The vehicle's tires and
wheels all must be the same size and type to generate accurate signals. Variations in tire and
wheel size can produce inaccurate wheel speed signals.
Improper speed sensor-to-tone wheel clearance can cause erratic speed sensor signals. The
speed sensor air gap is not adjustable, but should be checked when applicable. Wheel speed
sensor-to-tone wheel clearance specifications can be found in Specifications.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Page 4093
Wheel Speed Sensor: Testing and Inspection
Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following
possible causes. missing, chipped, or broken teeth
- contact with the wheel speed sensor
- wheel speed sensor to tone wheel alignment
- wheel speed sensor to tone wheel clearance
- excessive tone wheel runout
- tone wheel loose on its mounting surface
If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt
should be made to replace just the tone wheel.
If a rear tone wheel is found to need replacement on front-wheel-drive models, the tone wheel is
serviceable separately. If a rear tone wheel is found to need replacement on all-wheel-drive
models, the drive shaft must be replaced. No attempt should be made to replace just the tone
wheel.
If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before
replacing the wheel speed sensor or tone wheel.
Check the gap between the speed sensor head and the tone wheel to ensure it is within
specifications.
Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. If tone wheel
runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and
bearing. Replace as necessary.
Tone wheels are pressed onto their mounting surfaces and should not rotate independently from
the mounting surface. Replacement of the front driveshaft or rear hub and bearing is necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement
Front
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
Front Speed Sensor Cable Channel Bracket
3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame
rail.
CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not
to damage pins on connector.
Speed Sensor Cable To Vehicle Wiring Harness
4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect
speed sensor cable from vehicle wiring harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4096
Front Wheel Speed Sensor Attaching Bolt
5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor
head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON
SENSOR HEAD. Use a
hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free.
Front Wheel Speed Sensor Cable Routing
7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front
wheel speed sensor assembly from the vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as
shown may result in contact with moving parts and/or over extension of cables, resulting in an open
circuit.
1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure
speed sensor cable connector is fully seated and
locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut
tower.
CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the
channel bracket.
2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching
the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4.
Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to
steering knuckle on the rearward side of the
stabilizer bar link.
5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor
attaching bolt to a torque of 12 Nm (105 inch lbs.) 6. Check the air gap between the face of the
wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (.047 inches).
7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of
the base and ABS brake systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4097
Rear
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
CAUTION: When unplugging speed sensor cable from vehicle wiring harness, be careful not to
damage pins on the electrical connectors. Also inspect connectors for any signs of previous
damage.
Rear Speed Sensor Cable Connection To Vehicle Wiring Harness
3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from
vehicle wiring harness.
CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during removal of the speed sensor cable.
Speed Sensor Cable Attachment To Brake Flex Hose
4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4098
Right Rear Speed Sensor Cable Routing
5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the
axle flange, the brake tube clip and the routing clip
from the track bar bracket on the axle.
Rear Speed Sensor Routing Brackets And Clips
6. Remove the 2 rear wheel speed sensor cable/brake tube routing clips. Then unclip the speed
sensor cable from the routing clips on rear brake tube.
CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor
head in an attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the
sensor from side to side until free.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4099
Rear Wheel Speed Sensor Attaching Bolts
7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not
come loose, do not use pliers. Tap with screw driver
and hammer.
8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed
sensor assembly from vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as
shown may result in contact with moving parts and/or over extension of cables, resulting in an open
circuit.
1. Install wheel speed sensor head. Note the plastic anti rotation pin must be fully seated prior to
installing the attaching bolt.
CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must
be fully seated into the bearing flange.
Rear Wheel Speed Sensor Attaching Bolts
2. Install the wheel speed sensor head to bearing flange attaching bolt. Tighten the attaching bolt to
a torque 12 Nm (105 inch lbs.) 3. Check the air gap between the face of the wheel speed sensor
and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inches).
4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle.
The rear wheel speed sensor cable should be routed
under the rear brake tube.
CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during installation of the wheel speed
sensor cable.
5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear
speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4100
CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed
sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the
vehicle wiring harness, do not force the connectors together. If the connectors are forced together,
damage to the connectors will occur.
7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable
connector is fully seated and locked into vehicle wiring
harness connector.
8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into
the body hole. 9. Install the tire and wheel assembly on vehicle.
10. Road test vehicle to ensure proper operation of the base and ABS braking systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4101
Wheel Speed Sensor: Service and Repair Tone Wheel Replacement
This procedure is for the removal of the ABS rear tone wheel from the rear hub and bearing on
front wheel drive vehicles. Vehicles equipped with AWD have a tone wheel mounted on the
driveshaft outer constant velocity joint and it is serviced with the driveshaft.
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and
tire assembly. 3. Remove rear brake drum from the hub/bearing assembly.
Rear Wheel Speed Sensor
4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage
to the speed sensor during removal and
installation of the hub/bearing assembly.
Rear Hub/Bearing Mounting Bolts
5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4102
Removing Rear Hub/Bearing From Axle
6. Remove the hub/bearing assembly from the rear axle and brake support plate.
Tone Wheel Removal From Hub/Bearing Assembly
7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage
by the vise jaws. Mount the hub/bearing assembly
in a vise. Using Puller, Special Tool C-4693 installed as shown remove the tone wheel from the
hub/bearing assembly.
INSTALL
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4103
Installing Tone Wheel On Hub/Bearing Assembly
1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3.
Position Driver, Special Tool 6908-1 with undercut
side facing up on top of the tone wheel.
Correctly Installed Tone Wheel
2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3.
Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the
rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the
rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts
into hub/ bearing assembly. Tighten the 4 bolts in a
criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto
flange of rear axle.
6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.) 7. Install the rear
wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and
tighten to a torque of 12 Nm (105
inch lbs.).
8. Check the air gap between the face of the wheel speed sensor and the top surface of the tone
wheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inches).
9. Install the brake drum onto the rear hub/bearing assembly.
10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust
the rear brakes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Base Brake System Bleeding Procedures
Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures
Bleeding Base Brake Hydraulic System
NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For
bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake
System bleeding procedure in antilock brakes.
Pressure Bleeding Procedure
CAUTION:
- Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid
reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid
reservoir.
- Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the
hydraulic system for bleeding.
- When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be
removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid
reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system
is pressurized.
Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment.
Air Trapped In Brake System
When bleeding the brake system, some air may be trapped in the brake lines or valves far
upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow
of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out.
1. Remove the filler neck from the master cylinder fluid reservoir.
Pressure Bleeding Cap Installed On Master Cylinder
2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the
fluid reservoir of the master cylinder. Attach the
fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent.
3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar
containing fresh brake fluid.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure
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Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Base Brake System Bleeding Procedures > Page 4108
adequate removal of all trapped air from the brake hydraulic system.
(1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel
Rear Wheel Cylinder Bleeder Screw
4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow
of brake fluid.
CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid
discharge will NOT get all the air out.
5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free
flow is maintained in the hose and jar, this will
indicate a good bleed of the hydraulic system has been obtained.
6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel.
If pedal travel is excessive or has not been
improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to
monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the
brake system through the master cylinder.
7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Bleeding Without A Pressure Bleeder
NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper.
NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must
be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are
correctly adjusted.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure adequate removal of all trapped air from the brake
hydraulic system.
- Left Rear Wheel
- Right Front Wheel
- Right Rear Wheel
- Left Front Wheel
1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened.
2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens
the brake pedal will drop all the way to the floor.
3. Release the brake pedal only after the bleeder screw is closed.
4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence.
This should pass a sufficient amount of fluid to expel
all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder,
so it stays at a proper level so air will not enter the brake system through the master cylinder.
5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Base Brake System Bleeding Procedures > Page 4109
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
ANTILOCK BRAKE SYSTEM BLEEDING
The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS
though, particularly the ICU (HCU), should only be bled when the HCU is replaced or removed from
the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air.
Under most circumstances that require the bleeding of the brake hydraulic system, only the base
brake hydraulic system needs to be bled.
It is important to note that excessive air in the brake system will cause a soft or spongy feeling
brake pedal.
During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level
in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding
procedure and add DOT 3 brake fluid as required.
The ABS must be bled as two independent braking systems. The non-ABS portion of the brake
system with ABS is to be bled the same as any non-ABS system.
The ABS portion of the brake system must be bled separately. Use the following procedure to
properly bleed the brake hydraulic system including the ABS.
BLEEDING
When bleeding the ABS system, the following bleeding sequence must be followed to insure
complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure
or standard pressure bleeding equipment.
1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB scan
tool to the diagnostics connector. The diagnostic connector is located under the lower steering
column cover to the left of
the steering column.
3. Using the DRB, check to make sure the CAB does not have any fault codes stored. If it does,
clear them using the DRB.
WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR
BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A
CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF
BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE.
BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN
OPENED.
4. Bleed the base brake system using the standard pressure or manual bleeding procedure as
outlined in Base Brake Bleeding. 5. Using the DRB, select ANTILOCK BRAKES, followed by
MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When
the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed.
6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically
to prevent emptying, causing air to enter the
hydraulic system.
7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes
are operating correctly and that the brake pedal does not feel spongy.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications
Brake Pedal Assy: Specifications
Pedal Ratio ..........................................................................................................................................
............................................................................ 3.36
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information >
Description and Operation
Brake Warning Indicator: Description and Operation
The red BRAKE warning lamp is located in the instrument panel cluster and is used to indicate a
low brake fluid condition or that the parking brake is applied. In addition, the brake warning lamp is
turned on as a bulb check by the ignition switch every time the ignition switch is turned to the crank
position.
The warning lamp bulb is supplied a 12-volt ignition feed anytime the ignition switch is on. The bulb
is then illuminated by completing the ground circuit either through the parking brake switch, the
fluid level sensor in the master cylinder reservoir, or the ignition switch when it is turned to the
crank position.
The Brake Fluid Level switch is located in the brake fluid reservoir of the master cylinder assembly.
The purpose of the switch is to provide the driver with an early warning that brake fluid level in the
master cylinder fluid reservoir has dropped to below normal. This may indicate: Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the
hydraulic system.
- Brake shoe linings which have worn to a point requiring replacement.
As the brake fluid drops below the minimum level, the brake fluid level switch closes to ground the
brake warning light circuit. This will turn on the red BRAKE warning Light. At this time, the master
cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. If brake
fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake
hydraulic system should be checked for evidence of a leak.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information >
Description and Operation > Page 4116
Brake Warning Indicator: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear
Technical Service Bulletin # 05-003-01 Date: 010420
Brakes - Howl/Moan From The Rear
NUMBER: 05-003-01
GROUP: Brakes
DATE: Apr. 20, 2001
SUBJECT: Off Pedal Rear Brake Howl/Moan
OVERVIEW: This bulletin involves replacing the rear disc brake adapters.
MODELS: 1997 - 2000
(NS) Voyager/Caravan/Town & Country
1997 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Voyager/Caravan/Town & Country
2001 (RG) Chrysler Voyager (International Markets)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD).
SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot
maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from
the rear brake area.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: Could be one or more
Repair Procedure
1. Apply the parking brake and raise the vehicle on an appropriate hoist.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear > Page 4126
2. Remove right rear tire and wheel assembly.
3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V
joint (Fig. 1).
4. Remove the hub nut and washer from the stub shaft of the outer CV joint.
5. Mark the driveshaft inner joint location to the rear driveline module flange.
6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline
module (Fig. 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear > Page 4127
7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3).
8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is
removed by first compressing the inner joint on the driveshaft and removing it from the driveline
module. Then, slide the outer joint of the driveshaft out of the hub and bearing.
9. Release the parking brake.
10. Create slack in the rear parking brake cables by locking out the automatic adjuster as
described. Grasp the exposed section of the front park brake cable and pull downward on it. Then
install a pair of locking pliers on the front brake cable just rearward of the second body out rigger
bracket (Fig. 4).
11. Remove the park brake cable from the adapter by:
a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the
park brake cable.
b. RS/RG vehicles: removing the park brake mounting bolt.
12. Remove the end of the park brake cable from the actuator lever on the adapter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear > Page 4128
13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake
cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer.
14. Remove the disc brake caliper to adapter guide pin bolts.
15. Remove caliper from the adapter using the following procedure: a.
Rotate rear of caliper up.
b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front
abutment on the adapter.
16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose.
17. Remove the rotor from the hub/bearing.
18. Remove the four hub/bearing to axle mounting bolts.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS
THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE
HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT
POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A
HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE
CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC
BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING
WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER.
19. Remove the hub/bearing from the axle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear > Page 4129
20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two
cannot be separated by hand, use the following procedure:
a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1
on the cast housing of the hub/bearing (Fig. 6)
NOTE:
DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING.
b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the
caliper adapter.
21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a
vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any
part that is damaged or worn must be replaced by new parts.
22. Remove the park brake hardware (including the rubber access plug) from the adapter and
install park brake hardware on the new adapter.
23. Install the new adapter on the axle.
24. Install the hub/bearing on the end of the axle.
25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4
mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle.
Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.).
26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching
bolt to 12 Nm (105 in. lbs.).
27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of
rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the
hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output
shaft of the driveline module. Do not tighten mounting bolts at this time.
28. Install the park brake cable into its mounting hole in the adapter.
NOTE:
BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE
EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER.
29. Install the end of the park brake cable on the park brake actuator lever.
30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The
horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of
the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable
mounting bolt to the adapter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear > Page 4130
31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake
shoe to park brake drum clearance.
32. Install rotor on hub/bearing.
33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper
adapter by reversing the removal procedure in step 15.
CAUTION:
WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT
TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS.
34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts.
Torque to 22 Nm (192 in. lbs.).
35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and
hub nut on the stub shaft of the outer C/V joint.
36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle.
37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and
torquing the hub nut and driveshaft inner joint to driveline module mounting bolts.
38. Raise the vehicle.
39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a
torque of 61 Nm (45 ft. lbs.).
40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.).
41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V
joint.
42. Install tire and wheel assembly.
43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half
specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.).
44. Replace the left rear adapter using steps 2 through 43.
45. Lower the vehicle.
46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the
park brake cables.
CAUTION:
BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE
THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear
Technical Service Bulletin # 05-003-01 Date: 010420
Brakes - Howl/Moan From The Rear
NUMBER: 05-003-01
GROUP: Brakes
DATE: Apr. 20, 2001
SUBJECT: Off Pedal Rear Brake Howl/Moan
OVERVIEW: This bulletin involves replacing the rear disc brake adapters.
MODELS: 1997 - 2000
(NS) Voyager/Caravan/Town & Country
1997 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Voyager/Caravan/Town & Country
2001 (RG) Chrysler Voyager (International Markets)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD).
SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot
maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from
the rear brake area.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: Could be one or more
Repair Procedure
1. Apply the parking brake and raise the vehicle on an appropriate hoist.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4136
2. Remove right rear tire and wheel assembly.
3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V
joint (Fig. 1).
4. Remove the hub nut and washer from the stub shaft of the outer CV joint.
5. Mark the driveshaft inner joint location to the rear driveline module flange.
6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline
module (Fig. 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4137
7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3).
8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is
removed by first compressing the inner joint on the driveshaft and removing it from the driveline
module. Then, slide the outer joint of the driveshaft out of the hub and bearing.
9. Release the parking brake.
10. Create slack in the rear parking brake cables by locking out the automatic adjuster as
described. Grasp the exposed section of the front park brake cable and pull downward on it. Then
install a pair of locking pliers on the front brake cable just rearward of the second body out rigger
bracket (Fig. 4).
11. Remove the park brake cable from the adapter by:
a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the
park brake cable.
b. RS/RG vehicles: removing the park brake mounting bolt.
12. Remove the end of the park brake cable from the actuator lever on the adapter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4138
13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake
cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer.
14. Remove the disc brake caliper to adapter guide pin bolts.
15. Remove caliper from the adapter using the following procedure: a.
Rotate rear of caliper up.
b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front
abutment on the adapter.
16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose.
17. Remove the rotor from the hub/bearing.
18. Remove the four hub/bearing to axle mounting bolts.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS
THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE
HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT
POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A
HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE
CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC
BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING
WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER.
19. Remove the hub/bearing from the axle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4139
20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two
cannot be separated by hand, use the following procedure:
a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1
on the cast housing of the hub/bearing (Fig. 6)
NOTE:
DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING.
b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the
caliper adapter.
21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a
vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any
part that is damaged or worn must be replaced by new parts.
22. Remove the park brake hardware (including the rubber access plug) from the adapter and
install park brake hardware on the new adapter.
23. Install the new adapter on the axle.
24. Install the hub/bearing on the end of the axle.
25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4
mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle.
Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.).
26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching
bolt to 12 Nm (105 in. lbs.).
27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of
rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the
hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output
shaft of the driveline module. Do not tighten mounting bolts at this time.
28. Install the park brake cable into its mounting hole in the adapter.
NOTE:
BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE
EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER.
29. Install the end of the park brake cable on the park brake actuator lever.
30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The
horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of
the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable
mounting bolt to the adapter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4140
31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake
shoe to park brake drum clearance.
32. Install rotor on hub/bearing.
33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper
adapter by reversing the removal procedure in step 15.
CAUTION:
WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT
TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS.
34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts.
Torque to 22 Nm (192 in. lbs.).
35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and
hub nut on the stub shaft of the outer C/V joint.
36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle.
37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and
torquing the hub nut and driveshaft inner joint to driveline module mounting bolts.
38. Raise the vehicle.
39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a
torque of 61 Nm (45 ft. lbs.).
40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.).
41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V
joint.
42. Install tire and wheel assembly.
43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half
specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.).
44. Replace the left rear adapter using steps 2 through 43.
45. Lower the vehicle.
46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the
park brake cables.
CAUTION:
BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE
THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Page 4141
Brake Caliper: Specifications
Caliper Mounting Bolts 30 ft.lb
Guide Pin Bolts 195 in.lb
Bleeder Screw 125 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation
Brake Caliper: Service and Repair Removal and Installation
Front
NOTE: Before proceeding with this procedure, review Service Precautions.
REMOVAL
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
3. Remove the two caliper to steering knuckle guide pin bolts.
Caliper Assembly Mounting On Steering Knuckle (Typical)
4. Remove caliper from steering knuckle by first rotating free end of caliper away from steering
knuckle. Then slide opposite end of caliper out from
under machined abutment on steering knuckle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4144
Storing Front Disc Brake Caliper
5. Support caliper firmly to prevent weight of caliper from being supported by the brake fluid flex
hose. Supporting weight of caliper by the brake
fluid flex hose, can damage the flexible brake hose.
INSTALLATION
1. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose
Lubricant, or equivalent.
CAUTION: Use care when installing the caliper assembly onto the steering knuckle, so the seals
on the caliper guide pin bushings do not get damaged by the steering knuckle bosses.
2. Carefully position caliper and brake pad assemblies over brake rotor by hooking lower or upper
end of caliper over the machined abutment on
steering knuckle. Then rotate caliper into position at the top of the steering knuckle. Make sure that
caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses.
3. Install the caliper guide pin bolts and tighten to a torque of 22 Nm (195 inch lbs.). Extreme
caution should be taken not to cross thread the caliper
guide pin bolts.
4. Install the wheel and tire assembly. 5. Using a torque wrench, tighten the wheel mounting stud
nuts in proper sequence until all nuts are torqued to half specification. Repeat the
tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).
6. Remove jackstands or lower hoist. 7. Before moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake pedal.
Rear
NOTE: Before proceeding with this procedure, review Service Precautions.
- Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and
scratching or nicking of lining on the brake shoes.
REMOVAL
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies
from vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4145
Removing Caliper Guide Pin Bolts
3. Remove the disc brake caliper to adapter guide pin bolts.
Removing/Installing Caliper
4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter.
Correctly Supported Caliper
5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4146
INSTALLATION
NOTE: Step 1 below is only required when installing the disc brake caliper after new brake pads
have been installed.
1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both
adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. If
removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the hub.
CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting bosses.
4. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse
procedure for removal.
CAUTION: When installing guide pin bolts, extreme caution should be taken not to crossthread
them.
5. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.).
6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Repeat the tightening sequence to the full
specified torque of 129 Nm (95 ft. lbs.).
8. Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a
firm brake pedal to adequately stop vehicle.
9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and
to seat the linings.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4147
Brake Caliper: Service and Repair Disassembly and Assembly
Disassembly and Assembly
DISASSEMBLY
WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A
PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A
PRACTICE.
1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic
fluid cannot get on rotor. Place a small piece of
wood between the piston and caliper fingers.
2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold
down the brake pedal to any position beyond the first
inch of pedal travel. This will prevent loss of brake fluid from the master cylinder.
3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at
frame rail. Plug brake tube and remove piston from
opposite caliper using the same process as above for the first piston removal.
4. Disconnect the brake fluid flex hose from the caliper assembly.
CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will
cause bore distortion and binding of piston.
5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin
sleeves and guide pin bushings.
Fig. 10 Dust Boot Removal
7. Remove the piston dust boot from the caliper and discard.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4148
Removing Piston Seal From Caliper
8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston
bore. Discard old seal. Do not use a screw driver
or other metal tool for this operation, because of the possibility of scratching piston bore or burring
edges of seal groove.
9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint
residue can remain in caliper bore. Clean out all
drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must
be installed at assembly.
Honing Brake Caliper Piston Bore
10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can
usually be cleared of the light scratches or corrosion
using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone,
Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than
0.0254 mm (0.001 inch).
11. If the bore does not clean up within this specification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or
scored.
NOTE: ^
When using Caliper Honing Tool, Special Tool C-4095, coat the stones and bore with brake fluid.
After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary
brush.
^ Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the
caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time.
CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston
surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced.
12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is
evidence of scratches, pitting or physical damage.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4149
ASSEMBLY
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
1. Clamp caliper in a vise (with protective caps installed on jaws of vise).
Installing New Piston Seal In Caliper
2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should
be positioned at one area in groove and gently
worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD
PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled.
3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 4. Position
dust boot over piston after coating with brake fluid.
CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston
in the bore of the caliper.
Installing Piston Into Caliper Bore
5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6.
Position dust boot into the counterbore of the caliper assembly piston bore.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4150
7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special
Tool C-4171, drive boot into counterbore of the
caliper.
8. Install guide pin sleeves and bushings. 9. Install brake pads.
10. Before installing caliper assembly on vehicle, inspect brake rotor. If the rotor does not require
any servicing, install caliper assembly. 11. Install brake hose onto caliper using banjo bolt. Torque
the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs.). New seal washers
must always be used when installing brake hose to caliper.
12. Bleed the brake system.
Guide Pin Bushing Service
The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this
assembly can be serviced using the following procedure.
REMOVING CALIPER GUIDE PIN BUSHINGS
1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake
rotor.
Removing Inner Sleeve From Bushing
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4151
2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers.
Removing Bushing From Caliper
3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove
the bushing from the brake caliper housing.
INSTALLING CALIPER GUIDE PIN BUSHINGS
Folded Caliper Guide Pin Bushing
1. Fold the bushing in half lengthwise at the solid middle section of the bushing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4152
Installing Caliper Guide Pin Bushing
2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step
due to possible damage to the bushing.
Bushing Correctly Installed In Caliper
3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the
caliper housing. Flanges should be seated evenly
on both sides of the bushing hole.
4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an
equivalent.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4153
Fig 7 Installing Caliper Sleeves
5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in
sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing
through boot until one end of bushing is fully seated into seal
groove on one end of sleeve.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4154
Fig 8 Installed Caliper Bushing Sleeve
7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on
sleeve. Be sure other end of bushing did not come
out of seal grove in sleeve.
8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be
held between your fingers and easily slid back and
forth without the bushing unseating from the sleeve groove.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 4155
Brake Caliper: Service and Repair Cleaning and Inspection
Front
If a visual inspection does not adequately determine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the
calipers.
Remove the shoe and lining assemblies.
Combined shoe and lining thickness should be measured at the thinnest part of the assembly.
When a shoe and lining assembly is worn to a thickness of approximately 7.95 mm (0.313 inch) it
should be replaced.
Replace both shoe assemblies (inboard and outboard) on the front wheels. It is also necessary that
both front wheel shoe assembly sets be replaced, whenever shoe assemblies on either side of the
vehicle require replacement.
If a shoe assembly does not require replacement, reinstall it, making sure each shoe assembly is
returned to its original position.
Rear
Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any
ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak
is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if
scored.
Check the guide pin dust boots to determine if they are in good condition. Replace if they are
damaged, dry, or found to be brittle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Front
Brake Pad: Specifications Front
Brake Shoe Thickness Measurement
The combined brake shoe and lining material thickness should be measured at the thinnest part of
the assembly.
When a set of brake shoes are worn to a total thickness of approximately 7.95 mm (5/16 inch) or
less, they should be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Front > Page 4160
Brake Pad: Specifications Rear
Brake Shoe Thickness Measurement
The combined brake shoe and lining material thickness should be measured at the thinnest part of
the assembly.
When a set of brake shoes are worn to a total thickness of approximately 7.0 mm (9/32 inch), they
should be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front
Brake Pad: Service and Repair Front
NOTE: Before proceeding with this procedure, review Service Precautions.
REMOVAL
1. Remove the caliper from the disc brake rotor.
Removing Outboard Brake Pad From Caliper
2. Remove outboard brake pad by prying the pad retaining clip over raised area on caliper. Then
slide the pad down and off the caliper.
Removing Inboard Brake Pad From Piston
3. Pull inboard brake pad away from piston until retaining clip on brake pad is free from cavity in
caliper piston.
INSTALLATION
1. Completely retract caliper piston back into piston bore of caliper assembly. This is required for
caliper installation with new brake pad assemblies. 2. Remove the protective paper from the noise
suppression gasket on both the inner and outer brake pad assemblies (if equipped).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 4163
Front Brake Shoe Assembly Identification
NOTE: The inboard and outboard brake pads are not common, refer to the image for inboard and
outboard brake pad assembly identification.
Inboard Brake Shoe
3. Install the new inboard brake pad assembly into the caliper piston by firmly pressing into piston
bore. Be sure inboard brake pad assembly is
positioned squarely against face of caliper piston.
Installing Outboard Brake Shoe
4. Slide the new outboard brake pad assembly onto the caliper assembly. 5. Reinstall the caliper
on the brake rotor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 4164
Brake Pad: Service and Repair Rear
Removal and Installation
NOTE: Before proceeding with this procedure, review Service Precautions.
REMOVAL
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies
from vehicle.
Caliper Guide Pin Bolts
3. Remove the caliper to adapter guide pin bolts.
Removing/Installing Caliper
4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard anti-rattle clip out from under the front abutment on the adapter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 4165
Correctly Supported Caliper
5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. 6. If
the brake rotor needs to be removed it can be removed by removing the retainer clips and then
pulling the rotor straight off the wheel mounting
studs.
7. Remove the outboard brake pad from the caliper. Brake pad is removed by prying brake shoe
retaining clip over raised area on caliper and sliding
the brake pad off the caliper.
Removing Inboard Brake Pad From Piston
8. Remove inboard brake pad from caliper. Inboard pad is removed by pulling it out of the caliper
piston, until the retaining clip is free of the piston.
CALIPER INSPECTION
Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any
ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper
assembly and install a new seal and boot, (and piston if scored).
Check the caliper dust boot and caliper pin bushings to determine if they are in good condition.
Replace if they are damaged, dry, or found to be brittle.
INSTALLATION
NOTE: Step 1 below is only required when installing a caliper after new brake pads have been
installed.
1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both
adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. If
removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the hub.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 4166
Inboard Brake Shoe
4. Install the inboard brake pad into the caliper piston by firmly pressing it into the piston bore using
your thumbs. Be sure inboard pad is positioned
squarely against the face of the caliper piston.
5. Install the outboard brake pad on the disc brake caliper. Be sure the outboard pad is positioned
squarely against the outboard fingers of the caliper.
CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting bosses.
6. Carefully lower caliper and brake pads over rotor and onto adapter, reversing the removal
procedure.
CAUTION: When installing the caliper guide pin bolts extreme caution should be taken not to
crossthread them.
7. Install the caliper guide pin bolts. Tighten to a torque of 22 Nm (192 inch lbs.). 8. Install the
wheel and tire assembly. 9. Tighten the wheel mounting stud nuts in proper sequence until all nuts
are torqued to half specification. Then repeat the tightening sequence to the
full specified torque of 129 Nm (95 ft. lbs.).
10. Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a
firm brake pedal to adequately stop the vehicle.
11. Road test the vehicle and make several stops to wear off any foreign material on the brakes
and to seat the linings.
Cleaning and Inspection
LINING WEAR
If a visual inspection does not adequately determine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the
calipers.
Remove the rear disc brake pads.
The combined shoe and lining material thickness should be measured at the thinnest part of the
assembly.
When a set of brake pads are worn to a total thickness of approximately 7.0 mm (9/32 inch) they
should be replaced.
Replace both brake pad assemblies (inboard and outboard). It is necessary that both rear wheel
sets be replaced whenever brake shoe assemblies on either side are replaced.
If the brake shoe assemblies do not require replacement, reinstall, the assemblies making sure
each brake shoe is returned to the original position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications
Brake Rotor/Disc: Specifications Brake Rotor Specifications
Brake Rotor Specifications
BRAKE ROTOR Front Rear
BRAKE ROTOR TYPE Ventilated Solid
BRAKE ROTOR DIAMETER (14"/15" Standard) 260 mm (10.24 in.) 381 mm (15.0 in.)
BRAKE ROTOR DIAMETER (15" Heavy Duty) 283 mm (117.92 in.) ----ROTOR THICKNESS 23.87 - 24.13 mm (0.939 - 0.949 in.) 12.25 - 12.75 mm (0.482 - 0.502 in.)
MINIMUM ROTOR THICKNESS 22.4 mm (0.881 in.) 11.25 mm (0.443 in.)
Minimum allowable thickness markings are cast/stamped on an
un-machined outer surface of the rotor. These thickness
markings include 0.76 mm (0.030 in.) allowable rotor wear
beyond the recommended 0.76 mm (0.030 in.) of rotor
refacing.
ROTOR THICKNESS VARIATION 0.013 mm (0.0005 in.) 0.013 mm (0.0005 in.)
ROTOR RUNOUT * 0.08 mm (0.003 in.) 0.08 mm (0.003 in.)
* TIR - Total Indicator Reading (measured on vehicle)
ROTOR MICRO-FINISH 15 - 80 RMS 15 - 80 RMS
Front Rotor Thickness Markings
Rear Rotor Thickness Markings
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4170
Brake Rotor/Disc: Testing and Inspection
Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to
ensure proper brake action.
Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This
increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble.
When diagnosing a brake noise or pulsation, the machined disc braking surface should be checked
and inspected.
BRAKING SURFACE INSPECTION
Light braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the
rotor must be refaced or replaced.
Excessive wear and scoring of the rotor can cause improper lining contact on the rotor's braking
surface. If the ridges on the rotor are not removed before new brake pads are installed, improper
wear of the pads will result.
If a vehicle has not been driven for a period of time, the rotor's braking surface will rust in the areas
not covered by the brake pads at that time. Once the vehicle is driven, noise and chatter from the
disc brakes can result when the brakes are applied.
Some discoloration or wear of the rotor surface is normal and does not require resurfacing when
linings are replaced. If cracks or burned spots are evident, the rotor must be replaced.
ROTOR MINIMUM THICKNESS
Measure rotor thickness at the center of the brake pad contact surface. Replace the rotor if it is
worn below minimum thickness or if machining the rotor will cause its thickness to fall below
specifications.
CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness.
Minimum Brake Rotor Thickness Markings (Typical)
Minimum thickness specifications are cast on the rotor's unmachined surface. Limits can also be
found in SPECIFICATIONS.
ROTOR THICKNESS VARIATION
Thickness variation in a rotor's braking surface can result in pedal pulsation, chatter and surge.
This can also be caused by excessive runout in the rotor or the hub.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4171
Checking Rotor For Thickness
Rotor thickness variation measurements should be made in conjunction with measuring runout.
Measure thickness of the brake rotor at 12 equal points around the rotor braking surface with a
micrometer at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness
measurements vary by more than 0.013 mm (0.0005 inch), the rotor should be refaced or replaced.
ROTOR RUNOUT
Checking Rotor Runout
On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of
the rotor. (The hub and rotor runouts are separable). To measure rotor runout on the vehicle, first
remove the tire and wheel assembly. Reinstall the wheel mounting nuts on the studs, tightening the
rotor to the hub. Mount the Dial Indicator, Special Tool C-3339, with Mounting Adaptor, Special
Tool SP1910 on steering arm. The dial indicator plunger should contact braking surface of rotor
approximately ten millimeters from edge of rotor. Check lateral runout on both sides of the rotor,
marking the low and high spots on both. Runout limits can be found in SPECIFICATIONS.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4172
Marking Rotor And Wheel Stud
If runout is in excess of the specification, check the lateral runout of the hub face. Before removing
the rotor from the hub, place a chalk mark across both the rotor and the one wheel stud closest to
where the high runout measurement was taken. This way, the original mounting spot of the rotor on
the hub is indexed. Remove the rotor from the hub.
NOTE: Clean the hub face surface before checking runout. This provides a clean surface to get an
accurate indicator reading.
Checking Hub Runout
Mount Dial Indicator, Special Tool C-3339, and Mounting Adaptor, Special Tool SP-1910, to the
steering knuckle. Position the indicator stem so it contacts the hub face near the outer diameter.
Care must be taken to position stem outside of the stud circle, but inside of the chamfer on the hub
rim.
Hub runout should not exceed 0.03 mm (0.0012 inch). If runout exceeds this specification, the hub
must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4173
Index Rotor And Wheel Stud
Brake Rotor Limits
If the hub runout does not exceed this specification, install the rotor back on the hub, aligning the
chalk marks on the rotor with a wheel mounting stud, two studs apart from the original stud. Tighten
nuts in the proper sequence and torque to specifications.
Recheck brake rotor runout to see if the runout now within specifications.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4174
Brake Rotor/Disc: Service and Repair
MACHINING
Brake Rotor Limits
NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the
need is foreseen.
Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to
ensure proper brake action.
On-Car Brake Lathe
If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake
pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe, or replaced.
The use of a hub-mounted on-car brake lathe is highly recommended to eliminate the possibility of
excessive runout. It trues the brake rotor to the vehicle's hub and bearing.
Minimum Brake Rotor Thickness Markings (Typical)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 4175
Rear Rotor Thickness Markings
NOTE: All rotors have markings for minimum allowable thickness cast on an un-machined surface
of the rotor.
Minimum allowable thickness is the minimum thickness which the brake rotor machined surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness.
Before installation, verify the brake rotor face and the hub adapters are free of any chips, rust, or
contamination.
When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's
operating instructions is required.
Machine both sides of the brake rotor at the same time. Cutting both sides at the same time
minimizes the possibility of a tapered or uneven cut.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
Technical Service Bulletin # 05-001-06A Date: 060923
Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
NUMBER: 05-001-06 REV A
GROUP: Brakes
DATE: September 23, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH
9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER.
SUBJECT: Snow/Water Ingestion Into Rear Brake Drum
OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and
possible replacement of the rear brake shoes and drums.
MODELS:
2001 - 2006 (RS) Town & Country/Voyager/Caravan
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (CS) Chrysler Voyager (International Markets)
NOTE:
This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum
brakes) built on or before March 7, 2006 (MDH 0307XX).
SYMPTOM/CONDITION:
While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums
causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead
to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the
vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze
inside of the rear brake drums. When the parking brake has been applied the symptom is more
likely to occur.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4181
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Repair Procedure
1. Raise the vehicle on a suitable hoist.
2. Remove both rear wheel and tire assemblies.
3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the
drum.
4. Create slack in the rear park brake cables. With the park brake pedal in the released position
pull down and rearward on the core of the front park brake cable then install a pair of locking pliers
on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1).
5. Lower the vehicle so that it is low enough to access the brake pedal.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4182
6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of
travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is
removed from the wheel cylinder.
7. Raise the vehicle.
8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2)
9. Remove the adjustment lever from the leading brake shoe.
10. Remove the brake shoe lower return springs.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4183
11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly
(Fig. 3)
12. Remove the brake shoe to brake shoe upper return spring.
13. Remove the trailing brake shoe assembly hold down spring and pin.
14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating
lever and the park brake actuating strut, (Fig. 4)
15. Remove the automatic adjuster assembly from the leading shoe.
16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake
shoe assembly.
17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate
from the leading brake shoe and install it to the replacement brake shoe.
18. Disconnect the park brake cable from the park brake actuation lever.
19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be
removed unless the speed sensor is removed first.
CAUTION:
WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN
REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE
WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN
FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4184
20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park
brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5)
21. Disconnect the brake tube from the wheel cylinder.
22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the
wheel cylinder from the vehicle.
23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT
DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY
PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE
HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR
BEARING FAILURE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4185
24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool
8214, (Fig. 6), for RS skip to step 25.
a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing.
Put a dab of grease in the bolt pilot hole on the back of the tool.
b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special
Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until
the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when
pressing the bearing out of the axle.
c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt
against Special Tool 8214-1.
d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2
against Special Tool 8214-1. Proceed to step 26.
25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458
(Fig. 7)
a. Thread threaded guide pins into hub and bearing mounting holes.
b. Remove the two outboard spring plate bolts.
c. Using the spring plate bolts, install the screw mount, special tool 8458-2.
d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins.
e. Place a dab of grease in the dimple of the push plate.
f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the
hub and bearing assembly out of the axle by continuing to tighten the screw.
g. Remove the tool.
h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.).
26. Remove the hub/bearing from the rear axle and brake support plate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4186
27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual
adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard
the support plate.
28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle.
29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange
of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of
the vehicle.
30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing.
Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the
rear axle.
31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.).
NOTE:
FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS
ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO
OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH
POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE
REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N
04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97
HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT
REQUIRED.
32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder
opening in the revised brake support plate.
33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque
the 2 mounting bolts to 8 Nm (75 in. lbs.).
34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.)
35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to
12 Nm (105 in. lbs.).
36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange
and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA.
37. Install the rear park brake cable into its mounting hole in the brake support plate.
38. Install the park brake cable to the park brake actuator lever.
39. Lubricate the eight brake shoe contact areas on the support plate using the required special
Mopar Brake Lubricant p/n 04796269.
40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate.
41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake
actuator lever on the strut.
42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing
brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing
brake shoe on the brake support plate.
43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate.
44. Install the upper brake shoe to brake shoe return spring.
CAUTION:
WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST
BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED
ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC
ADJUSTER WILL BE AFFECTED.
45. Install the tension clip attaching the upper return spring to the automatic adjuster.
46. Install the lower brake shoe to brake shoe return springs.
47. Install the automatic adjuster lever on the leading brake shoe.
48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe.
49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic
adjuster assembly.
50. Repeat steps 8 through 48 for the other side rear brake assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4187
51. When all components of both rear brake assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable.
52. Adjust the rear brakes so they do not interfere with installing the brake drums.
53. Install both rear brake drums. Install the original drums as removed unless their condition
justifies turning or replacement.
54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135
Nm (100 ft. lbs.).
55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is
against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward
rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned.
56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against
the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting
lever or distort the lever spring.
57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to
eliminate the drag felt when the tire/wheel assembly is turned.
58. Install the adjusting/inspection hole rubber plug(s) saved in step 26
59. Repeat steps 55 through 58 for the other side rear brake.
60. Perform the base brake bleeding procedure described in the appropriate service manual.
61. Lower the vehicle to the floor.
62. Push the park brake pedal down fully and release to adjust the park brake cables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Page 4188
Backing Plate: Specifications
To Rear Axle Mounting Bolts ...............................................................................................................
................................................. 130 Nm (95 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Service and Repair > Removal
Backing Plate: Service and Repair Removal
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and
tire. 3. Remove brake drum from hub/bearing. 4. Remove brake shoes from brake support plate. 5.
Disconnect the park brake cable from the park brake actuation lever.
6. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage
to the speed sensor during removal and
installation of the hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be
removed unless the speed sensor is removed first.
CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on
the tone wheel will result in false ABS cycling and corrosion of the tone wheel.
7. Remove the 4 bolts attaching the hub/bearing to the flange of the rear axle.
CAUTION: Corrosion may occur between the hub/bearing and the axle. If this occurs the
hub/bearing will be difficult to remove from the axle. If the hub/ bearing will not come out of the axle
by pulling on it by hand, do not pound on the hub/bearing to remove it from the axle. Pounding on
the hub/bearing to remove it from the axle will damage the hub/bearing. This damage will result in
noise or failure of the bearing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Service and Repair > Removal > Page 4191
8. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 and
following procedure to press the hub/bearing out of
the axle. a. Place Special Tool 8214-1 over tone wheel and against cast flange of hub/bearing.
Put a dab of grease in the bolt pilot hole on the back of Special Tool 8214-1.
b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. Special
Tool 8214-2 should be against and supported by
the axle plate when pressing the wheel bearing out of the axle. If Special Tool 8214-2 will not fit
into the hole in the end casting, file or grind the flashing from the hole until tool fits properly.
c. Align bolt in Special Tool 8214-2 with pilot hole in Special Tool 8214-1. Tighten bolt against
Special Tool 8214-1. d. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool
8214-2 against Special Tool 8214-1.
9. Remove the hub/bearing from the rear axle and brake support plate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Service and Repair > Removal > Page 4192
10. Using a suitable tool such as a 14 mm box wrench or an aircraft type hose clamp, compress
the flared legs on park brake cable retainer, then pull
the park brake cable out of brake support plate.
11. Lower vehicle enough to access the brake pedal. 12. Using a brake pedal depressor, move
brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out
of
master cylinder when brake tube is removed from wheel cylinder.
13. Raise vehicle.
14. Disconnect brake tube from wheel cylinder. 15. Remove the 2 bolts attaching the wheel
cylinder to the brake support plate. 16. Remove the wheel cylinder from the brake support plate.
17. Remove the rear brake support plate from the rear axle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Service and Repair > Removal > Page 4193
Backing Plate: Service and Repair Installation
1. Install the 4 hub/bearing to axle mounting bolts into the mounting holes in the flange of the rear
axle.
2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle.
NOTE: When installing the hub/bearing on the rear axle, the bearing is to be installed with the thick
bearing mounting flange pointing down.
3. Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing.
Tighten the 4 bolts in a criss-cross pattern until the
hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle.
4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.) 5. Apply sealant
such as Mopar Gasket-In-A-Tube or an equivalent around the wheel cylinder opening in the brake
support plate. 6. Install wheel cylinder onto brake support and tighten the wheel cylinder to brake
support plate attaching bolts to 8 Nm (75 inch lbs.). 7. Install brake tube on rear wheel cylinder.
Tighten tube nut to a torque of 16 Nm (142 inch lbs.). 8. Install the rear wheel speed sensor on the
rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm
(105
inch lbs.).
9. Install the rear park brake cable into its mounting hole in the rear brake support plate.
10. Install the park brake cable on the park brake actuation lever. 11. Install the rear brake shoes
on the brake support plate. 12. Install brake drum onto hub/bearing. 13. Install wheel and tire. 14.
Tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 15. Adjust the rear brakes. 16. Bleed the entire
brake system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
Technical Service Bulletin # 05-001-06A Date: 060923
Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
NUMBER: 05-001-06 REV A
GROUP: Brakes
DATE: September 23, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH
9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER.
SUBJECT: Snow/Water Ingestion Into Rear Brake Drum
OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and
possible replacement of the rear brake shoes and drums.
MODELS:
2001 - 2006 (RS) Town & Country/Voyager/Caravan
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (CS) Chrysler Voyager (International Markets)
NOTE:
This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum
brakes) built on or before March 7, 2006 (MDH 0307XX).
SYMPTOM/CONDITION:
While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums
causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead
to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the
vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze
inside of the rear brake drums. When the parking brake has been applied the symptom is more
likely to occur.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4198
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Repair Procedure
1. Raise the vehicle on a suitable hoist.
2. Remove both rear wheel and tire assemblies.
3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the
drum.
4. Create slack in the rear park brake cables. With the park brake pedal in the released position
pull down and rearward on the core of the front park brake cable then install a pair of locking pliers
on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1).
5. Lower the vehicle so that it is low enough to access the brake pedal.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4199
6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of
travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is
removed from the wheel cylinder.
7. Raise the vehicle.
8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2)
9. Remove the adjustment lever from the leading brake shoe.
10. Remove the brake shoe lower return springs.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4200
11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly
(Fig. 3)
12. Remove the brake shoe to brake shoe upper return spring.
13. Remove the trailing brake shoe assembly hold down spring and pin.
14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating
lever and the park brake actuating strut, (Fig. 4)
15. Remove the automatic adjuster assembly from the leading shoe.
16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake
shoe assembly.
17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate
from the leading brake shoe and install it to the replacement brake shoe.
18. Disconnect the park brake cable from the park brake actuation lever.
19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be
removed unless the speed sensor is removed first.
CAUTION:
WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN
REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE
WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN
FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4201
20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park
brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5)
21. Disconnect the brake tube from the wheel cylinder.
22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the
wheel cylinder from the vehicle.
23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT
DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY
PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE
HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR
BEARING FAILURE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4202
24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool
8214, (Fig. 6), for RS skip to step 25.
a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing.
Put a dab of grease in the bolt pilot hole on the back of the tool.
b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special
Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until
the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when
pressing the bearing out of the axle.
c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt
against Special Tool 8214-1.
d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2
against Special Tool 8214-1. Proceed to step 26.
25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458
(Fig. 7)
a. Thread threaded guide pins into hub and bearing mounting holes.
b. Remove the two outboard spring plate bolts.
c. Using the spring plate bolts, install the screw mount, special tool 8458-2.
d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins.
e. Place a dab of grease in the dimple of the push plate.
f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the
hub and bearing assembly out of the axle by continuing to tighten the screw.
g. Remove the tool.
h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.).
26. Remove the hub/bearing from the rear axle and brake support plate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4203
27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual
adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard
the support plate.
28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle.
29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange
of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of
the vehicle.
30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing.
Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the
rear axle.
31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.).
NOTE:
FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS
ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO
OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH
POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE
REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N
04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97
HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT
REQUIRED.
32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder
opening in the revised brake support plate.
33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque
the 2 mounting bolts to 8 Nm (75 in. lbs.).
34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.)
35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to
12 Nm (105 in. lbs.).
36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange
and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA.
37. Install the rear park brake cable into its mounting hole in the brake support plate.
38. Install the park brake cable to the park brake actuator lever.
39. Lubricate the eight brake shoe contact areas on the support plate using the required special
Mopar Brake Lubricant p/n 04796269.
40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate.
41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake
actuator lever on the strut.
42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing
brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing
brake shoe on the brake support plate.
43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate.
44. Install the upper brake shoe to brake shoe return spring.
CAUTION:
WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST
BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED
ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC
ADJUSTER WILL BE AFFECTED.
45. Install the tension clip attaching the upper return spring to the automatic adjuster.
46. Install the lower brake shoe to brake shoe return springs.
47. Install the automatic adjuster lever on the leading brake shoe.
48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe.
49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic
adjuster assembly.
50. Repeat steps 8 through 48 for the other side rear brake assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4204
51. When all components of both rear brake assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable.
52. Adjust the rear brakes so they do not interfere with installing the brake drums.
53. Install both rear brake drums. Install the original drums as removed unless their condition
justifies turning or replacement.
54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135
Nm (100 ft. lbs.).
55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is
against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward
rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned.
56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against
the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting
lever or distort the lever spring.
57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to
eliminate the drag felt when the tire/wheel assembly is turned.
58. Install the adjusting/inspection hole rubber plug(s) saved in step 26
59. Repeat steps 55 through 58 for the other side rear brake.
60. Perform the base brake bleeding procedure described in the appropriate service manual.
61. Lower the vehicle to the floor.
62. Push the park brake pedal down fully and release to adjust the park brake cables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Page 4205
Brake Drum: Specifications Brake Drum Specifications
Brake Drum Specifications
DRUM DIAMETER 250 mm (9.84 in.)
DRUM DIAMETER (Maximum) Cast/stamped into outside surface of drum
This marking includes 0.76 mm (0.030 inch) for allowable
drum wear beyond the recommended 1.52 mm (0.060 inch) of
drum refacing.
DIAMETER VARIATION (Maximum) 0.090 mm (0.004 in.)
DRUM RUNOUT (on lathe) 0.15 mm (0.006 in.)
INITIAL DRUM MACHINING CUTS 0.13 mm (0.005 in.)
Initial machining cuts should be limited to 0.13 mm (0.005
in.) at a time as heavier feed rates can produce taper and
surface variation.
FINISH DRUM MACHINING CUTS 0.0254 mm (0.001 in.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Brake Drum Removal and Installation
Brake Drum: Service and Repair Brake Drum Removal and Installation
REMOVAL
1. Remove the tire and wheel assembly from the vehicle. Remove the park brake cable for the
wheel of the vehicle that is being worked on, from the
parking brake cable equalizer). This is required to gain access to the star wheel. If the cable is not
removed from the equalizer, the cable and spring inside of the brake drum is in the way of the star
wheel.
2. Remove the rear brake shoe adjusting hole cover plug. 3. Insert a thin screwdriver into brake
adjusting hole and hold adjusting lever away from notches of adjusting screw star wheel. 4. Insert
Tool C-3784 into brake adjusting hole and engage notches of brake adjusting screw star wheel.
Release brake adjustment by prying down
with adjusting tool.
5. Remove rear brake drum from rear hub/bearing assembly.
INSTALLATION
1. Adjust brake shoe assemblies so as not to interfere with brake drum installation. 2. Install the
rear brake drums on the hubs. 3. Adjust rear brake shoes.
Parking Brake Cable Equalizer
4. Install the removed park brake cable back on the park brake cable equalizer. 5. Install wheel and
tire. 6. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to the
full specified torque of 129 Nm (95 ft. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Brake Drum Removal and Installation > Page 4208
Brake Drum: Service and Repair Brake Drum Refinishing
Measure the runout and diameter of the rear brake using only accurate measuring equipment.
There should be no variation in the drum diameter greater than 0.090 mm (0.004 inch). Drum
runout should not exceed 0.15 mm (0.006 inch) out of round. If the drum runout or diameter
variation exceed these values the drum should be refaced. For best results in eliminating the
irregularities that cause brake roughness and surge, the amount of material removed during a
single cut should be limited to 0.13 mm (0.005 inch). When the entire braking surface has been
cleaned. A final cut of 0.0254 mm (0.001 inch) will assure a good drum surface providing the
equipment used is capable of the precision required for resurfacing brake drums. Deeper cuts are
permissible for the sole purpose of removing deep score marks. Do not reface more than 1.52 mm
(0.060 inch) over the standard drum diameter.
All drums will show markings of maximum allowable diameter. For example, a drum will have a
marking of MAXIMUM DIAMETER 251.55 mm (9.90 inch). This marking includes 0.76 mm (0.030
inch) for allowable drum wear beyond the recommended 1.52 mm (0.060 inch) of drum refacing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
Technical Service Bulletin # 05-001-06A Date: 060923
Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
NUMBER: 05-001-06 REV A
GROUP: Brakes
DATE: September 23, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH
9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER.
SUBJECT: Snow/Water Ingestion Into Rear Brake Drum
OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and
possible replacement of the rear brake shoes and drums.
MODELS:
2001 - 2006 (RS) Town & Country/Voyager/Caravan
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (CS) Chrysler Voyager (International Markets)
NOTE:
This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum
brakes) built on or before March 7, 2006 (MDH 0307XX).
SYMPTOM/CONDITION:
While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums
causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead
to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the
vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze
inside of the rear brake drums. When the parking brake has been applied the symptom is more
likely to occur.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4213
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Repair Procedure
1. Raise the vehicle on a suitable hoist.
2. Remove both rear wheel and tire assemblies.
3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the
drum.
4. Create slack in the rear park brake cables. With the park brake pedal in the released position
pull down and rearward on the core of the front park brake cable then install a pair of locking pliers
on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1).
5. Lower the vehicle so that it is low enough to access the brake pedal.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4214
6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of
travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is
removed from the wheel cylinder.
7. Raise the vehicle.
8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2)
9. Remove the adjustment lever from the leading brake shoe.
10. Remove the brake shoe lower return springs.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4215
11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly
(Fig. 3)
12. Remove the brake shoe to brake shoe upper return spring.
13. Remove the trailing brake shoe assembly hold down spring and pin.
14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating
lever and the park brake actuating strut, (Fig. 4)
15. Remove the automatic adjuster assembly from the leading shoe.
16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake
shoe assembly.
17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate
from the leading brake shoe and install it to the replacement brake shoe.
18. Disconnect the park brake cable from the park brake actuation lever.
19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be
removed unless the speed sensor is removed first.
CAUTION:
WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN
REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE
WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN
FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4216
20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park
brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5)
21. Disconnect the brake tube from the wheel cylinder.
22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the
wheel cylinder from the vehicle.
23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT
DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY
PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE
HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR
BEARING FAILURE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4217
24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool
8214, (Fig. 6), for RS skip to step 25.
a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing.
Put a dab of grease in the bolt pilot hole on the back of the tool.
b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special
Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until
the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when
pressing the bearing out of the axle.
c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt
against Special Tool 8214-1.
d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2
against Special Tool 8214-1. Proceed to step 26.
25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458
(Fig. 7)
a. Thread threaded guide pins into hub and bearing mounting holes.
b. Remove the two outboard spring plate bolts.
c. Using the spring plate bolts, install the screw mount, special tool 8458-2.
d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins.
e. Place a dab of grease in the dimple of the push plate.
f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the
hub and bearing assembly out of the axle by continuing to tighten the screw.
g. Remove the tool.
h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.).
26. Remove the hub/bearing from the rear axle and brake support plate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4218
27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual
adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard
the support plate.
28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle.
29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange
of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of
the vehicle.
30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing.
Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the
rear axle.
31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.).
NOTE:
FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS
ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO
OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH
POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE
REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N
04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97
HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT
REQUIRED.
32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder
opening in the revised brake support plate.
33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque
the 2 mounting bolts to 8 Nm (75 in. lbs.).
34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.)
35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to
12 Nm (105 in. lbs.).
36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange
and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA.
37. Install the rear park brake cable into its mounting hole in the brake support plate.
38. Install the park brake cable to the park brake actuator lever.
39. Lubricate the eight brake shoe contact areas on the support plate using the required special
Mopar Brake Lubricant p/n 04796269.
40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate.
41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake
actuator lever on the strut.
42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing
brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing
brake shoe on the brake support plate.
43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate.
44. Install the upper brake shoe to brake shoe return spring.
CAUTION:
WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST
BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED
ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC
ADJUSTER WILL BE AFFECTED.
45. Install the tension clip attaching the upper return spring to the automatic adjuster.
46. Install the lower brake shoe to brake shoe return springs.
47. Install the automatic adjuster lever on the leading brake shoe.
48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe.
49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic
adjuster assembly.
50. Repeat steps 8 through 48 for the other side rear brake assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 4219
51. When all components of both rear brake assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable.
52. Adjust the rear brakes so they do not interfere with installing the brake drums.
53. Install both rear brake drums. Install the original drums as removed unless their condition
justifies turning or replacement.
54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135
Nm (100 ft. lbs.).
55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is
against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward
rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned.
56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against
the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting
lever or distort the lever spring.
57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to
eliminate the drag felt when the tire/wheel assembly is turned.
58. Install the adjusting/inspection hole rubber plug(s) saved in step 26
59. Repeat steps 55 through 58 for the other side rear brake.
60. Perform the base brake bleeding procedure described in the appropriate service manual.
61. Lower the vehicle to the floor.
62. Push the park brake pedal down fully and release to adjust the park brake cables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Page 4220
Brake Shoe: Specifications
As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch)
of the rivet heads.
Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Page 4221
Brake Shoe: Adjustments
NOTE: Normally, self adjusting drum brakes will not require manual brake shoe adjustment.
Although in the event of a brake reline it is advisable to make the initial adjustment manually to
speed up the adjusting time.
1. Raise the vehicle so that the rear wheels are free to turn.
Park Brake Cable Equalizer
Remove the park brake cable for the wheel of the vehicle that is being worked on from the park
brake cable equalizer. This is required to gain access to the star wheel. If the cable is not removed
from the equalizer, the cable and spring inside of the brake drum is in the way of the star wheel.
2. Remove rubber plug, from rear brake adjusting hole, in the rear brake support plate. 3. Be sure
parking brake lever is fully released. 4. Insert Brake Adjusting Special Tool C-3784 or equivalent
through the adjusting hole in support plate and against star wheel of adjusting screw.
Move handle of tool upward until a slight drag is felt when road wheel is rotated.
5. Insert a thin screwdriver or piece of welding rod into brake adjusting hole. Push adjusting lever
out of engagement with star wheel. Care should be
taken so as not to bend adjusting lever or distort lever spring. While holding adjusting lever out of
engagement, back off star wheel to ensure a free wheel with no brake shoe drag.
6. Repeat above adjustment at the other rear wheel. 7. Install adjusting hole rubber plug in rear
brake support plates. 8. Install park brake cables on park brake cable equalizer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation
Brake Shoe: Service and Repair Brake Shoe Removal and Installation
Removal
NOTE: Before proceeding with this procedure, review Service Precautions.
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove the rear wheel and tire
assemblies from the vehicle. 3. Remove rear brake drum to hub retaining nuts (if equipped). Then
remove rear brake drums from hub and bearing assemblies.
NOTE: When creating slack in the park brake cables by locking out the automatic adjuster, be sure
that the park brake pedal is in the released (most upward) position.
4. Create slack in the rear park brake cables. Slack is created by grabbing exposed section of front
park brake cable and pulling it down and
rearward. Slack is maintained in the park brake cable by installing a pair of locking pliers on the
park brake cable just rearward of only the rear body outrigger bracket.
5. Remove adjustment lever spring from adjustment lever and front brake shoe.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 4224
6. Remove adjustment lever from leading brake shoe.
7. Remove the brake shoe to brake shoe lower return springs.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 4225
8. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly.
9. Remove the brake shoe to brake shoe upper return spring.
10. Remove the trailing brake shoe assembly to brake support plate hold down spring and pin from
the brake shoe assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 4226
11. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating
lever and park brake actuating strut. Remove the
automatic adjuster assembly from the leading brake shoe.
12. Remove the leading brake shoe assembly to brake support plate hold down spring and pin from
the brake shoe. Remove the leading brake shoe
from the brake support plate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 4227
13. Remove the park brake actuator from the leading brake shoe and transfer to the replacement
brake shoe.
Installation
1. Lubricate the eight shoe contact areas on the support plate and anchor, using the required
special Mopar Brake Lubricant. 2. Install leading brake shoe on brake support plate. Install the
leading brake shoe hold down spring and pin on the brake shoe.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 4228
3. Install the park brake actuator strut on the leading brake shoe. Then install the park brake
actuator lever on the strut. 4. Install the automatic adjuster screw on the leading brake shoe. Then
install the trailing brake shoe on the park brake actuating lever and park brake
actuating strut. Position trailing brake shoe on brake support plate.
5. Install the brake shoe hold down pin and spring on the trailing brake shoe. 6. Install the brake
shoe to brake shoe upper return spring.
CAUTION: When installing the tension clip on the automatic adjuster, it must be located on only the
threaded area of the adjuster assembly. If it is located on a non-threaded area of the adjuster, the
function of the automatic adjuster will be affected.
7. Install the tension clip attaching the upper return spring to the automatic adjuster assembly. 8.
Install the brake shoe to brake shoe lower return springs on the brake shoes. 9. Install automatic
adjustment lever on the leading brake shoe of the rear brake assembly.
10. Install the actuating spring on the automatic adjustment lever and leading brake shoe
assembly. 11. Verify that the automatic adjuster lever has positive contact with the star wheel on
the automatic adjuster assembly. 12. When all components of both rear brake assemblies are
correctly and fully installed, remove the locking pliers from the front park brake cable. 13. Adjust
brake shoes assemblies so as not to interfere with brake drum installation. 14. Install the rear brake
drums on the hubs. 15. Adjust rear brake shoes. 16. Install the wheel and tire assembly. 17. Push
the park brake pedal to the floor once and release pedal. This will automatically remove the slack
from and correctly adjust the park brake
cables.
18. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to the
full specified torque of 130 Nm (95 ft. lbs.).
19. Road test vehicle. The automatic adjuster will continue the brake adjustment during the road
test of the vehicle.
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Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 4229
Brake Shoe: Service and Repair Cleaning and Inspection
LINING
1. Remove the tire and wheel assembly from the vehicle.
2. Remove the rear brake adjusting hole cover plug. 3. Insert a thin screwdriver into brake adjusting
hole to hold the adjusting lever away from the notches on the adjusting screw star wheel. 4. Insert
Tool C-3784 into brake adjusting hole and engage notches of brake adjusting screw star wheel.
Release brake by prying down with adjusting
tool.
5. Remove the rear brake drum from the rear hub/bearing assembly. 6. Inspect brake lining for
wear, shoe alignment, and or contamination from grease or brake fluid.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Specifications
Wheel Cylinder: Specifications
Diameter 3/4 in
To Support Plate Mounting Bolts 75 in.lb
Bleeder Screw 80 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation
Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation
REMOVE
1. In case of a leak, remove brake shoes. Replace if soaked with grease or brake fluid.
2. Disconnect the rear brake hydraulic tube from the wheel cylinder. 3. Remove the rear wheel
cylinder attaching bolts. Pull wheel cylinder assembly off the brake support plate.
INSTALL
1. Apply Mopar Gasket In-A-Tube or equivalent sealant around wheel cylinder mounting surface in
brake support plate. 2. Install wheel cylinder onto brake support, and tighten the wheel cylinder to
brake support plate attaching bolts to 8 Nm (75 inch lbs.). 3. Attach hydraulic brake tube to wheel
cylinder, and tighten tube to wheel cylinder fitting to 16 Nm (142 inch lbs.). 4. Install brake shoes on
support plate. 5. Install rear brake drum onto rear hub. Install rear wheel and tire assembly, tighten
wheel stud nuts to 129 Nm (95 ft. lbs.). 6. Adjust the rear brakes. 7. Bleed the entire brake system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4235
Wheel Cylinder: Service and Repair Cleaning and Inspection
With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak.
Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel
cylinders should be completely cleaned, inspected, and new parts installed.
If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake
shoes must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4236
Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul
DISASSEMBLE
To disassemble the wheel cylinders, proceed as follows:
Fig 3 Wheel Cylinder
1. Pry boots away from cylinders and remove. 2. Press in on one piston to force out opposite
piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston
that
remain in the wheel cylinder.
3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol, (DO NOT USE ANY
PETROLEUM BASE SOLVENTS) clean
thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and
pitting. (Do not use a rag as lint from the rag will stick to bore surfaces.)
4. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. Cylinder
walls that have light scratches, or show signs of
corrosion, can usually be cleaned with crocus cloth, using a circular motion. Black stains on the
cylinder walls are caused by piston cups and will not impair operation of cylinder.
ASSEMBLE
Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. If
the boots are deteriorated, cracked or do not fit tightly on the pistons or the cylinder casting, install
new boots.
1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the
wheel cylinder cups with only Mopar Protect A-Cup Lubricant. 3. Install expansion spring with cup
expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other.
4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of
each cup, already installed. 5. Install a boot over each end of cylinder. Be careful not to damage
boot during installation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Base Brake System Bleeding Procedures
Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures
Bleeding Base Brake Hydraulic System
NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For
bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake
System bleeding procedure in antilock brakes.
Pressure Bleeding Procedure
CAUTION:
- Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid
reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid
reservoir.
- Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the
hydraulic system for bleeding.
- When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be
removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid
reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system
is pressurized.
Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment.
Air Trapped In Brake System
When bleeding the brake system, some air may be trapped in the brake lines or valves far
upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow
of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out.
1. Remove the filler neck from the master cylinder fluid reservoir.
Pressure Bleeding Cap Installed On Master Cylinder
2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the
fluid reservoir of the master cylinder. Attach the
fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent.
3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar
containing fresh brake fluid.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Base Brake System Bleeding Procedures > Page 4242
adequate removal of all trapped air from the brake hydraulic system.
(1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel
Rear Wheel Cylinder Bleeder Screw
4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow
of brake fluid.
CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid
discharge will NOT get all the air out.
5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free
flow is maintained in the hose and jar, this will
indicate a good bleed of the hydraulic system has been obtained.
6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel.
If pedal travel is excessive or has not been
improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to
monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the
brake system through the master cylinder.
7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Bleeding Without A Pressure Bleeder
NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper.
NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must
be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are
correctly adjusted.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure adequate removal of all trapped air from the brake
hydraulic system.
- Left Rear Wheel
- Right Front Wheel
- Right Rear Wheel
- Left Front Wheel
1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened.
2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens
the brake pedal will drop all the way to the floor.
3. Release the brake pedal only after the bleeder screw is closed.
4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence.
This should pass a sufficient amount of fluid to expel
all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder,
so it stays at a proper level so air will not enter the brake system through the master cylinder.
5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Base Brake System Bleeding Procedures > Page 4243
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
ANTILOCK BRAKE SYSTEM BLEEDING
The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS
though, particularly the ICU (HCU), should only be bled when the HCU is replaced or removed from
the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air.
Under most circumstances that require the bleeding of the brake hydraulic system, only the base
brake hydraulic system needs to be bled.
It is important to note that excessive air in the brake system will cause a soft or spongy feeling
brake pedal.
During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level
in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding
procedure and add DOT 3 brake fluid as required.
The ABS must be bled as two independent braking systems. The non-ABS portion of the brake
system with ABS is to be bled the same as any non-ABS system.
The ABS portion of the brake system must be bled separately. Use the following procedure to
properly bleed the brake hydraulic system including the ABS.
BLEEDING
When bleeding the ABS system, the following bleeding sequence must be followed to insure
complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure
or standard pressure bleeding equipment.
1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB scan
tool to the diagnostics connector. The diagnostic connector is located under the lower steering
column cover to the left of
the steering column.
3. Using the DRB, check to make sure the CAB does not have any fault codes stored. If it does,
clear them using the DRB.
WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR
BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A
CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF
BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE.
BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN
OPENED.
4. Bleed the base brake system using the standard pressure or manual bleeding procedure as
outlined in Base Brake Bleeding. 5. Using the DRB, select ANTILOCK BRAKES, followed by
MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When
the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed.
6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically
to prevent emptying, causing air to enter the
hydraulic system.
7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes
are operating correctly and that the brake pedal does not feel spongy.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear
Technical Service Bulletin # 05-003-01 Date: 010420
Brakes - Howl/Moan From The Rear
NUMBER: 05-003-01
GROUP: Brakes
DATE: Apr. 20, 2001
SUBJECT: Off Pedal Rear Brake Howl/Moan
OVERVIEW: This bulletin involves replacing the rear disc brake adapters.
MODELS: 1997 - 2000
(NS) Voyager/Caravan/Town & Country
1997 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Voyager/Caravan/Town & Country
2001 (RG) Chrysler Voyager (International Markets)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD).
SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot
maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from
the rear brake area.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: Could be one or more
Repair Procedure
1. Apply the parking brake and raise the vehicle on an appropriate hoist.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear > Page 4252
2. Remove right rear tire and wheel assembly.
3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V
joint (Fig. 1).
4. Remove the hub nut and washer from the stub shaft of the outer CV joint.
5. Mark the driveshaft inner joint location to the rear driveline module flange.
6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline
module (Fig. 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear > Page 4253
7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3).
8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is
removed by first compressing the inner joint on the driveshaft and removing it from the driveline
module. Then, slide the outer joint of the driveshaft out of the hub and bearing.
9. Release the parking brake.
10. Create slack in the rear parking brake cables by locking out the automatic adjuster as
described. Grasp the exposed section of the front park brake cable and pull downward on it. Then
install a pair of locking pliers on the front brake cable just rearward of the second body out rigger
bracket (Fig. 4).
11. Remove the park brake cable from the adapter by:
a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the
park brake cable.
b. RS/RG vehicles: removing the park brake mounting bolt.
12. Remove the end of the park brake cable from the actuator lever on the adapter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear > Page 4254
13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake
cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer.
14. Remove the disc brake caliper to adapter guide pin bolts.
15. Remove caliper from the adapter using the following procedure: a.
Rotate rear of caliper up.
b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front
abutment on the adapter.
16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose.
17. Remove the rotor from the hub/bearing.
18. Remove the four hub/bearing to axle mounting bolts.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS
THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE
HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT
POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A
HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE
CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC
BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING
WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER.
19. Remove the hub/bearing from the axle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear > Page 4255
20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two
cannot be separated by hand, use the following procedure:
a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1
on the cast housing of the hub/bearing (Fig. 6)
NOTE:
DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING.
b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the
caliper adapter.
21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a
vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any
part that is damaged or worn must be replaced by new parts.
22. Remove the park brake hardware (including the rubber access plug) from the adapter and
install park brake hardware on the new adapter.
23. Install the new adapter on the axle.
24. Install the hub/bearing on the end of the axle.
25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4
mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle.
Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.).
26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching
bolt to 12 Nm (105 in. lbs.).
27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of
rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the
hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output
shaft of the driveline module. Do not tighten mounting bolts at this time.
28. Install the park brake cable into its mounting hole in the adapter.
NOTE:
BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE
EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER.
29. Install the end of the park brake cable on the park brake actuator lever.
30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The
horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of
the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable
mounting bolt to the adapter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear > Page 4256
31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake
shoe to park brake drum clearance.
32. Install rotor on hub/bearing.
33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper
adapter by reversing the removal procedure in step 15.
CAUTION:
WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT
TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS.
34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts.
Torque to 22 Nm (192 in. lbs.).
35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and
hub nut on the stub shaft of the outer C/V joint.
36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle.
37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and
torquing the hub nut and driveshaft inner joint to driveline module mounting bolts.
38. Raise the vehicle.
39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a
torque of 61 Nm (45 ft. lbs.).
40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.).
41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V
joint.
42. Install tire and wheel assembly.
43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half
specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.).
44. Replace the left rear adapter using steps 2 through 43.
45. Lower the vehicle.
46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the
park brake cables.
CAUTION:
BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE
THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear
Technical Service Bulletin # 05-003-01 Date: 010420
Brakes - Howl/Moan From The Rear
NUMBER: 05-003-01
GROUP: Brakes
DATE: Apr. 20, 2001
SUBJECT: Off Pedal Rear Brake Howl/Moan
OVERVIEW: This bulletin involves replacing the rear disc brake adapters.
MODELS: 1997 - 2000
(NS) Voyager/Caravan/Town & Country
1997 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Voyager/Caravan/Town & Country
2001 (RG) Chrysler Voyager (International Markets)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD).
SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot
maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from
the rear brake area.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: Could be one or more
Repair Procedure
1. Apply the parking brake and raise the vehicle on an appropriate hoist.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4262
2. Remove right rear tire and wheel assembly.
3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V
joint (Fig. 1).
4. Remove the hub nut and washer from the stub shaft of the outer CV joint.
5. Mark the driveshaft inner joint location to the rear driveline module flange.
6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline
module (Fig. 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4263
7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3).
8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is
removed by first compressing the inner joint on the driveshaft and removing it from the driveline
module. Then, slide the outer joint of the driveshaft out of the hub and bearing.
9. Release the parking brake.
10. Create slack in the rear parking brake cables by locking out the automatic adjuster as
described. Grasp the exposed section of the front park brake cable and pull downward on it. Then
install a pair of locking pliers on the front brake cable just rearward of the second body out rigger
bracket (Fig. 4).
11. Remove the park brake cable from the adapter by:
a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the
park brake cable.
b. RS/RG vehicles: removing the park brake mounting bolt.
12. Remove the end of the park brake cable from the actuator lever on the adapter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4264
13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake
cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer.
14. Remove the disc brake caliper to adapter guide pin bolts.
15. Remove caliper from the adapter using the following procedure: a.
Rotate rear of caliper up.
b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front
abutment on the adapter.
16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose.
17. Remove the rotor from the hub/bearing.
18. Remove the four hub/bearing to axle mounting bolts.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS
THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE
HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT
POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A
HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE
CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC
BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING
WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER.
19. Remove the hub/bearing from the axle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4265
20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two
cannot be separated by hand, use the following procedure:
a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1
on the cast housing of the hub/bearing (Fig. 6)
NOTE:
DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING.
b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the
caliper adapter.
21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a
vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any
part that is damaged or worn must be replaced by new parts.
22. Remove the park brake hardware (including the rubber access plug) from the adapter and
install park brake hardware on the new adapter.
23. Install the new adapter on the axle.
24. Install the hub/bearing on the end of the axle.
25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4
mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle.
Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.).
26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching
bolt to 12 Nm (105 in. lbs.).
27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of
rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the
hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output
shaft of the driveline module. Do not tighten mounting bolts at this time.
28. Install the park brake cable into its mounting hole in the adapter.
NOTE:
BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE
EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER.
29. Install the end of the park brake cable on the park brake actuator lever.
30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The
horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of
the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable
mounting bolt to the adapter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 4266
31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake
shoe to park brake drum clearance.
32. Install rotor on hub/bearing.
33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper
adapter by reversing the removal procedure in step 15.
CAUTION:
WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT
TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS.
34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts.
Torque to 22 Nm (192 in. lbs.).
35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and
hub nut on the stub shaft of the outer C/V joint.
36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle.
37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and
torquing the hub nut and driveshaft inner joint to driveline module mounting bolts.
38. Raise the vehicle.
39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a
torque of 61 Nm (45 ft. lbs.).
40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.).
41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V
joint.
42. Install tire and wheel assembly.
43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half
specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.).
44. Replace the left rear adapter using steps 2 through 43.
45. Lower the vehicle.
46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the
park brake cables.
CAUTION:
BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE
THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Page 4267
Brake Caliper: Specifications
Caliper Mounting Bolts 30 ft.lb
Guide Pin Bolts 195 in.lb
Bleeder Screw 125 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation
Brake Caliper: Service and Repair Removal and Installation
Front
NOTE: Before proceeding with this procedure, review Service Precautions.
REMOVAL
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
3. Remove the two caliper to steering knuckle guide pin bolts.
Caliper Assembly Mounting On Steering Knuckle (Typical)
4. Remove caliper from steering knuckle by first rotating free end of caliper away from steering
knuckle. Then slide opposite end of caliper out from
under machined abutment on steering knuckle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4270
Storing Front Disc Brake Caliper
5. Support caliper firmly to prevent weight of caliper from being supported by the brake fluid flex
hose. Supporting weight of caliper by the brake
fluid flex hose, can damage the flexible brake hose.
INSTALLATION
1. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose
Lubricant, or equivalent.
CAUTION: Use care when installing the caliper assembly onto the steering knuckle, so the seals
on the caliper guide pin bushings do not get damaged by the steering knuckle bosses.
2. Carefully position caliper and brake pad assemblies over brake rotor by hooking lower or upper
end of caliper over the machined abutment on
steering knuckle. Then rotate caliper into position at the top of the steering knuckle. Make sure that
caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses.
3. Install the caliper guide pin bolts and tighten to a torque of 22 Nm (195 inch lbs.). Extreme
caution should be taken not to cross thread the caliper
guide pin bolts.
4. Install the wheel and tire assembly. 5. Using a torque wrench, tighten the wheel mounting stud
nuts in proper sequence until all nuts are torqued to half specification. Repeat the
tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).
6. Remove jackstands or lower hoist. 7. Before moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake pedal.
Rear
NOTE: Before proceeding with this procedure, review Service Precautions.
- Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and
scratching or nicking of lining on the brake shoes.
REMOVAL
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies
from vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4271
Removing Caliper Guide Pin Bolts
3. Remove the disc brake caliper to adapter guide pin bolts.
Removing/Installing Caliper
4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter.
Correctly Supported Caliper
5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4272
INSTALLATION
NOTE: Step 1 below is only required when installing the disc brake caliper after new brake pads
have been installed.
1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both
adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. If
removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the hub.
CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting bosses.
4. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse
procedure for removal.
CAUTION: When installing guide pin bolts, extreme caution should be taken not to crossthread
them.
5. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.).
6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Repeat the tightening sequence to the full
specified torque of 129 Nm (95 ft. lbs.).
8. Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a
firm brake pedal to adequately stop vehicle.
9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and
to seat the linings.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4273
Brake Caliper: Service and Repair Disassembly and Assembly
Disassembly and Assembly
DISASSEMBLY
WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A
PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A
PRACTICE.
1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic
fluid cannot get on rotor. Place a small piece of
wood between the piston and caliper fingers.
2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold
down the brake pedal to any position beyond the first
inch of pedal travel. This will prevent loss of brake fluid from the master cylinder.
3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at
frame rail. Plug brake tube and remove piston from
opposite caliper using the same process as above for the first piston removal.
4. Disconnect the brake fluid flex hose from the caliper assembly.
CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will
cause bore distortion and binding of piston.
5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin
sleeves and guide pin bushings.
Fig. 10 Dust Boot Removal
7. Remove the piston dust boot from the caliper and discard.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4274
Removing Piston Seal From Caliper
8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston
bore. Discard old seal. Do not use a screw driver
or other metal tool for this operation, because of the possibility of scratching piston bore or burring
edges of seal groove.
9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint
residue can remain in caliper bore. Clean out all
drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must
be installed at assembly.
Honing Brake Caliper Piston Bore
10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can
usually be cleared of the light scratches or corrosion
using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone,
Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than
0.0254 mm (0.001 inch).
11. If the bore does not clean up within this specification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or
scored.
NOTE: ^
When using Caliper Honing Tool, Special Tool C-4095, coat the stones and bore with brake fluid.
After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary
brush.
^ Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the
caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time.
CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston
surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced.
12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is
evidence of scratches, pitting or physical damage.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4275
ASSEMBLY
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
1. Clamp caliper in a vise (with protective caps installed on jaws of vise).
Installing New Piston Seal In Caliper
2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should
be positioned at one area in groove and gently
worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD
PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled.
3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 4. Position
dust boot over piston after coating with brake fluid.
CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston
in the bore of the caliper.
Installing Piston Into Caliper Bore
5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6.
Position dust boot into the counterbore of the caliper assembly piston bore.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4276
7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special
Tool C-4171, drive boot into counterbore of the
caliper.
8. Install guide pin sleeves and bushings. 9. Install brake pads.
10. Before installing caliper assembly on vehicle, inspect brake rotor. If the rotor does not require
any servicing, install caliper assembly. 11. Install brake hose onto caliper using banjo bolt. Torque
the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs.). New seal washers
must always be used when installing brake hose to caliper.
12. Bleed the brake system.
Guide Pin Bushing Service
The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this
assembly can be serviced using the following procedure.
REMOVING CALIPER GUIDE PIN BUSHINGS
1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake
rotor.
Removing Inner Sleeve From Bushing
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4277
2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers.
Removing Bushing From Caliper
3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove
the bushing from the brake caliper housing.
INSTALLING CALIPER GUIDE PIN BUSHINGS
Folded Caliper Guide Pin Bushing
1. Fold the bushing in half lengthwise at the solid middle section of the bushing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4278
Installing Caliper Guide Pin Bushing
2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step
due to possible damage to the bushing.
Bushing Correctly Installed In Caliper
3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the
caliper housing. Flanges should be seated evenly
on both sides of the bushing hole.
4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an
equivalent.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4279
Fig 7 Installing Caliper Sleeves
5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in
sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing
through boot until one end of bushing is fully seated into seal
groove on one end of sleeve.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4280
Fig 8 Installed Caliper Bushing Sleeve
7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on
sleeve. Be sure other end of bushing did not come
out of seal grove in sleeve.
8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be
held between your fingers and easily slid back and
forth without the bushing unseating from the sleeve groove.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 4281
Brake Caliper: Service and Repair Cleaning and Inspection
Front
If a visual inspection does not adequately determine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the
calipers.
Remove the shoe and lining assemblies.
Combined shoe and lining thickness should be measured at the thinnest part of the assembly.
When a shoe and lining assembly is worn to a thickness of approximately 7.95 mm (0.313 inch) it
should be replaced.
Replace both shoe assemblies (inboard and outboard) on the front wheels. It is also necessary that
both front wheel shoe assembly sets be replaced, whenever shoe assemblies on either side of the
vehicle require replacement.
If a shoe assembly does not require replacement, reinstall it, making sure each shoe assembly is
returned to its original position.
Rear
Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any
ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak
is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if
scored.
Check the guide pin dust boots to determine if they are in good condition. Replace if they are
damaged, dry, or found to be brittle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications
Brake Fluid: Specifications
BRAKE FLUID
Specification ........................................................................................................................................
.................................................................. DOT 3
Standard ..............................................................................................................................................
........................................................... SAE J1703
NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703
standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake
system. Use only Mopar brake fluid or an equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An
open container of brake fluid will absorb moisture from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission
fluid, power steering fluid, etc.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications > Page 4285
Brake Fluid: Service Precautions
SAFETY PRECAUTIONS
WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following
actions:
* Eye Contact-rinse eyes thoroughly with water.
* Skin Contact-wash skin with soap and water.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications > Page 4286
Brake Fluid: Testing and Inspection
CAUTION:
The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic
fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid
absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the
vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake
fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an
equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid
separates into layers, there is mineral oil or other fluid contamination of the brake fluid.
If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the
rubber parts or components containing rubber coming into contact with the brake fluid. This
includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS
hydraulic control unit (HCU), and all hydraulic fluid hoses.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications > Page 4287
Brake Fluid: Service and Repair
MASTER CYLINDER FLUID LEVEL CHECK
Check master cylinder reservoir fluid level a minimum of twice annually.
Master Cylinder Fluid Level Marks
Master cylinder reservoirs are marked with the words FULL and ADD to indicate proper brake fluid
fill level of the master cylinder.
If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the
master cylinder fluid reservoir. When filling master cylinder fluid reservoir do not fill the filler neck of
the fluid reservoir with brake fluid.
Use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to
DOT 3 specifications.
Do not use brake fluid with a lower boiling point, as brake failure could result during prolonged hard
braking.
Use only brake fluid that was stored in a tightly sealed container.
Do not use petroleum-based fluid because seal damage will result. Petroleum based fluids would
be items such as engine oil, transmission fluid, power steering fluid etc.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Service and Repair
Brake Fluid Level Sensor/Switch: Service and Repair
The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for
replacement of the brake fluid level switch.
REMOVAL
Fluid Level Sensor Electrical Connection
1. Remove wiring harness connector from brake fluid reservoir level switch.
Master Cylinder Brake Fluid Level Switch
2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With
retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master
cylinder brake fluid reservoir.
INSTALLATION
1. Insert the brake fluid level switch into brake fluid reservoir. Be sure switch is pushed in until
retaining tabs lock it to the brake fluid reservoir. 2. Connect the vehicle wiring harness connector to
the brake fluid level switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications
Brake Hose/Line: Specifications
To Caliper Banjo Bolt ...........................................................................................................................
................................................... 48 Nm (35 ft. lbs.) Intermediate Bracket ..........................................
................................................................................................................................. 12 Nm (105 inch
lbs.) Tube Nuts To Fittings And Components
............................................................................................................................................. 17 Nm
(145 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > Page 4294
Brake Hose/Line: Description and Operation
The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid
developed by the master cylinder to the wheel brakes of the vehicle. The chassis tubes are steel
with a corrosion resistant coating applied to the external surfaces and the flex hoses are made of
reinforced rubber. The rubber flex hoses allow for the movement of the vehicle's suspension.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > Page 4295
Brake Hose/Line: Testing and Inspection
Flexible rubber hose is used at both front brakes and at the rear axle. Inspection of brake hoses
should be performed whenever the brake system is serviced and every 7,500 miles or 12 months,
whichever comes first (every engine oil change). Inspect hydraulic brake hoses for surface
cracking, scuffing, or worn spots. If the fabric casing of the rubber hose becomes exposed due to
cracks or abrasions in the rubber hose cover, the hose should be replaced immediately. Eventual
deterioration of the hose can take place with possible burst failure. Faulty installation can cause
twisting, resulting in wheel, tire, or chassis interference.
The steel brake tubing should be inspected periodically for evidence of physical damage or contact
with moving or hot components.
The flexible brake tube sections used on this vehicle in the primary and secondary tubes from the
master cylinder to the ABS hydraulic control unit connections, and the chassis brake tubes
between the hydraulic control unit and the proportioning valve must also be inspected. This flexible
tubing must be inspected for kinks, fraying and its contact with other components of the vehicle or
contact with the body of the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring
Brake Hose/Line: Service and Repair Brake Tubing Repair/Tube Flaring
General Information
CAUTION: When repairing brake chassis lines or flex hoses, the correct fasteners must be used to
attach the routing clips or hoses to the front suspension cradle. The fasteners used to attach
components to the front suspension cradle have an anti-corrosion coating due to the suspension
cradle being made of aluminum. Only Mopar replacement fasteners with the required anti-corrosion
coating are to be used if a replacement fastener is required when installing a brake chassis line or
flex hose.
Only double wall 4.75 mm (3/16 inches) steel tubing with Al-rich/ZW-AC alloy coating and the
correct tube nuts are to be used for replacement of a hydraulic brake tube.
NOTE: On vehicles equipped with traction control, the primary and secondary hydraulic tubes
between the master cylinder and the hydraulic control unit are 6 mm (15/64 inches). These tubes
are also coated with the Al-rich/ZW-AC alloy and must be replaced with tubes having the same
anti-corrosion coating. Be sure the correct tube nuts are used for the replacement of these
hydraulic brake tubes.
Care should be taken when repairing brake tubing, to be sure the proper bending and flaring tools
and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving
components or into hot areas. All tubes should be properly attached with recommended retaining
clips.
If the primary or secondary brake line from the master cylinder to the ABS Hydraulic Control Unit,
or the flexible brake lines between the hydraulic control unit and the proportioning valve require
replacement only the original factory brake lines containing a flexible section can be used. This is
required due to the movement of the front suspension cradle while the vehicle is in motion.
Cutting And Flaring Of Brake Fluid Tubing
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Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 4298
Tube End Properly Prepared For Flaring
Using Tubing Cutter, Special Tool C-3478-A or equivalent, cut off damaged seat or tubing. Ream
out any burrs or rough edges showing on inside of tubing. This will make the ends of tubing square
and ensure better seating of flared end tubing. Place tube nut on tubing before flaring the tubing.
Double Inverted Tubing Flares
Inverted Flare And ISO Flare
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Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 4299
Inverted Double Wall Flare And ISO Flare Tubing Connections
To make a double inverted tubing flare. Open handles of Flaring Tool, Special Tool C-4047 or
equivalent. Rotate jaws of tool until the mating jaws of tubing size are centered between vertical
posts on tool. Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to
handle as this will lock tubing in place.
Place gauge (Form A) on edge over end of brake tubing. Push tubing through jaws until end of
tubing contacts the recessed notch in gauge matching the tubing size. Squeeze handles of flaring
tool and lock tubing in place. Place 3/16 inch plug of gauge (A) down in end of tubing. Swing
compression disc over gauge and center tapered flaring screw in recess of disc. Screw in until plug
gauge has seated on jaws of flaring tool. This action has started to invert the extended end of the
tubing. Remove gauge and continue to screw down until tool is firmly seated in tubing. Remove
tubing from flaring tool and inspect seat. Replace any damaged tube routing clips.
ISO Tubing Flares
CAUTION: All ISO style tubing flares and are of metric dimensions. When performing any service
procedures on vehicles using ISO style tubing flares, metric size tubing of 4.75 mm MUST be used
with metric ISO tube flaring equipment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 4300
To create a (metric) ISO style tubing flare, Use Snap-On Flaring Tool TFM-428, or equivalent. See
and proceed with the steps listed below. Be sure to place the tubing nut on the tube before flaring
the tubing. 1. Carefully prepare the end of the tubing to be flared. Be sure the end of the tubing to
be flared is square and all burrs on the inside of the tubing are
removed. This preparation is essential to obtain the correct form of a (metric) ISO tubing flare.
2. Open jaws of the Flaring Tool. Align the mating size jaws of the flaring tool around the size of the
tubing to be flared. Close the jaws of the
Flaring Tool around the tubing to keep it from sliding out of the flaring tool, but do not lock the
tubing in place.
3. Position the tubing in the jaws of the Flaring Tool so that it is flush with the top surface of the
flaring tool bar assembly. 4. Install the correct size adapter for the brake tubing being flared, on the
feed screw of the yoke assembly. Center the yoke and adapter over the end
of the tubing. Apply lubricant to the adapter area that contacts brake tubing. Making sure the
adapter pilot is fully inserted in the end of the brake tubing. Screw in the feed screw of the yoke
assembly until the adapter has seated squarely on the surface of the bar assembly. This process
has created the (metric) ISO tubing flare.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 4301
Brake Hose/Line: Service and Repair Brake Tubing/Hose Replacement
CAUTION: When installing brake chassis lines or flex hoses on the vehicle, the correct fasteners
must be used to attach the routing clips or hoses to the front suspension cradle. The fasteners
used to attach components to the front suspension cradle have an anti-corrosion coating due to the
suspension cradle being made of aluminum. Only Mopar replacement fasteners with the required
anti-corrosion coating are to be used if a replacement fastener is required when installing a brake
chassis line or flex hose.
Only double wall 4.75mm (3/16 inches) steel tubing with Al-rich/ZW-AC alloy coating and the
correct tube nuts are to be used for replacement of a hydraulic brake tube.
NOTE: On vehicles equipped with traction control, the primary and secondary hydraulic tubes
between the master cylinder and the hydraulic control unit are 6 mm (15/64 inches). These tubes
are also coated with the Al-rich/ZW-AC alloy and must be replaced with tubes having the same
anti-corrosion coating. Be sure that the correct tube nuts are used for the replacement of these
hydraulic brake tubes.
Care should be taken when replacing brake tubing, to be sure the proper bending and flaring tools
and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving
components or into hot areas. All tubes should be properly attached with recommended retaining
clips.
If the primary or secondary brake tube from the master cylinder to the ABS Hydraulic Control Unit
(HCU) or the brake tubes from the HCU to the proportioning valve require replacement, only the
original factory brake line containing the flexible section can be used as the replacement part. This
is required due to cradle movement while the vehicle is in motion.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Specifications > With Antilock Brakes
Brake Proportioning/Combination Valve: Specifications With Antilock Brakes
To Frame Rail Attaching Bolts
............................................................................................................................................................
14 Nm (125 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Specifications > With Antilock Brakes > Page 4306
Brake Proportioning/Combination Valve: Specifications Without Antilock Brakes
To Mounting Bracket Attaching Bolts
................................................................................................................................................ 23 Nm
(200 inch lbs.) Actuator Assembly Adjustment Nut
........................................................................................................................................................ 5
Nm (45 inch lbs.) Mounting Bracket To Frame Rail Bolts
.............................................................................................................................................. 17 Nm
(150 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Fixed Proportioning Valve
Brake Proportioning/Combination Valve: Description and Operation Fixed Proportioning Valve
The hydraulic brake system on all vehicles is diagonally split. This means that the left front and
right rear brakes are on one hydraulic circuit with the right front and left rear brakes on the other
hydraulic circuit.
On vehicles equipped with ABS brakes, the brake systems Hydraulic Control Unit (HCU) is
mounted to the front suspension crossmember on the driver's side of the vehicle. The (HCU) acts
as the hydraulic system junction block, diagonally splitting the brakes hydraulic system.
Fixed Proportioning Valve Location
All vehicles equipped with ABS brakes use 2 fixed proportioning valves. The fixed proportioning
valves are mounted in a common bracket on the left frame rail at the rear of the vehicle.
FIXED PROPORTIONING VALVE OPERATION
The fixed proportioning valve is made out of aluminum and has an integral mounting bracket. The
fixed proportioning valve is non-serviceable component and must be replaced as an assembly if
found to be functioning improperly.
The fixed proportioning valve is mounted to the bottom of the left rear frame rail, just forward of the
rear shock absorber to frame rail mounting location. The proportioning valve has 2 inlet ports for
brake fluid coming from the ABS modulator, and 2 outlet ports for brake fluid going to the rear
wheel brakes.
The fixed proportioning valve operates by allowing full hydraulic pressure to the rear brakes up to a
set point, called the valve's split point. Beyond this split point the proportioning valve reduces the
amount of hydraulic pressure to the rear brakes according to a certain ratio.
Thus, on light brake pedal applications the proportioning valve allows approximately equal brake
hydraulic pressure to be supplied to both the front and rear brakes. On heavier brake pedal
applications though, the proportioning valve will control hydraulic pressure to the rear brakes, so
that hydraulic pressure at the rear brakes will be lower than that at the front brakes. This controlled
hydraulic pressure to the rear brakes prevents excessive rear wheel ABS cycling during moderate
stops.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Fixed Proportioning Valve > Page 4309
Brake Proportioning/Combination Valve: Description and Operation Height Sensing Proportioning
Valve
CAUTION: The use of after-market load leveling or load capacity increasing devices on this vehicle
are prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height
sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes.
This inappropriate reduction in hydraulic pressure potentially could result in increased stopping
distance of the vehicle.
Junction Block Location
On vehicles not equipped with ABS brakes, the brake systems Hydraulic Control Unit (HCU) is
replaced by a junction block. The junction block is made of aluminum and is mounted to the front
suspension crossmember on the driver's side of the vehicle in the same location as the (HCU) on
an ABS equipped vehicle. The junction block is permanently attached to its mounting bracket and
must be replaced as an assembly with its mounting bracket. The junction block is used for
diagonally splitting the brake's hydraulic system.
Height Sensing Proportioning Valve
Vehicles not equipped with ABS brakes use a height sensing proportioning valve. The height
sensing proportioning valve is mounted on the left frame rail at the rear of the vehicle. The height
sensing proportioning valve uses an actuator assembly to attach the proportioning valve to the left
rear spring for sensing changes in vehicle height.
HEIGHT SENSING PROPORTIONING VALVE OPERATION
The height sensing proportioning valve regulates the hydraulic pressure to the rear brakes. The
proportioning valve regulates the pressure by sensing the load condition of the vehicle through the
movement of the proportioning valve actuator assembly. The actuator assembly is mounted
between the height sensing proportioning valve and the actuator bracket on the left rear leaf spring.
As the rear height of the vehicle changes depending on the load the vehicle is carrying the height
change is transferred to the height sensing proportioning valve. This change in vehicle height is
transferred through the movement of the left rear leaf spring. As the position of the left rear leaf
spring changes this movement is transferred through the actuator bracket to the actuator assembly
and then to the proportioning valve.
Thus, the height sensing proportioning valve allows the brake system to maintain the optimal front
to rear brake balance regardless of the vehicle load condition. Under a light load condition,
hydraulic pressure to the rear brakes is minimized. As the load condition of the vehicle increases,
so does the hydraulic pressure to the rear brakes.
The proportioning valve section of the valve operates by transmitting full input hydraulic pressure to
the rear brakes up to a certain point, called the split point. Beyond the split point the proportioning
valve reduces the amount of hydraulic pressure to the rear brakes according to a certain ratio.
Thus, on light brake applications, approximately equal hydraulic pressure will be transmitted to the
front and rear brakes. At heavier brake
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Fixed Proportioning Valve > Page 4310
applications, the hydraulic pressure transmitted to the rear brakes will be lower then the front
brakes. This will prevent premature rear wheel lock-up and skid.
The height sensing section of the valve thus changes the split point of the proportioning valve,
based on the rear suspension height of the vehicle. When the height of the rear suspension is low,
the proportioning valve interprets this as extra load and the split point of the proportioning valve is
raised to allow more rear braking. When the height of the rear suspension is high, the proportioning
valve interprets this as a lightly loaded vehicle and the split point of the proportioning valve is
lowered and rear braking is reduced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Fixed Proportioning Valve > Page 4311
Brake Proportioning/Combination Valve: Description and Operation Proportioning Valve
Proportioning Valve
There are two proportioning valves used in the antilock brake system. One valve controls each rear
braking circuit, but both are serviced as one assembly. Both proportioning valves are mounted
together on a bracket that is attached to the left frame rail near the left rear shock absorber.
The ABS proportioning valves function the same as standard proportioning valves.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Testing and Inspection > With Antilock Brakes
Brake Proportioning/Combination Valve: Testing and Inspection With Antilock Brakes
A vehicle equipped with ABS uses a fixed proportioning valve.
On a vehicle equipped with ABS, premature or excessive rear wheel ABS cycling may be an
indication that the brake fluid pressure to the rear brakes is above the desired output.
Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also,
ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify
that the brakes shoe assemblies on a vehicle being tested, are either Original Equipment
Manufacturers (OEM), or original replacement brake shoe assemblies meeting the OEM lining
material specification. The vehicles brake system is not balanced for after market brake shoe
assembly lining material.
If brake shoe assembly lining material is of satisfactory condition, and of the correct material
specification, check for proper proportioning valve function using the following procedure:
Rear Brake Proportioning Valve And Brake Tube Locations
1. Road test vehicle to be sure the vehicle is truly exhibiting a condition of excessive rear wheel
ABS cycling. Since ABS cycles both rear brakes
together both proportioning valves of the assembly must be tested. Use the following procedure to
test the proportioning valve:
2. Remove one of the chassis brake lines coming from the ABS modulator, at the proportioning
valve assembly. Remove the hydraulic brake line
going to one of the rear wheels of the vehicle from the proportioning valve.
3. Remove the 2 bolts attaching the proportioning valve to the frame rail.
CAUTION: When lowering the proportioning valve, care must be taken not to kink any of the
chassis brake lines.
4. Carefully lower the proportioning valve for clearance to install the proportioning valve test fittings.
Proportioning Valve Test Fitting Installation
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Testing and Inspection > With Antilock Brakes > Page 4314
5. Install the required fitting from Pressure Test Fittings, Special Tool 6833 into the inlet port of the
proportioning valve assembly, from which the
chassis brake line was removed. Install the removed chassis brake line into the Pressure Test
Fitting. Install the required fitting from Pressure Test Fittings, Special Tool 6833 into the required
outlet port of the proportioning valve. Install the required fitting from Pressure Test Fittings, Special
Tool 6833 into the required outlet port of the proportioning valve. Then install the removed chassis
brake line into the Pressure Test Fitting.
Pressure Gauges Installed On Pressure Test Fittings
6. Install a pressure gauge from Gauge Set, Special Tool C-4007-A into each pressure test fitting.
Bleed air out of hose from pressure test fittings to
pressure gauges, at the pressure gauges. Then bleed air out of the brake line being tested, at that
rear wheel cylinder.
7. With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000
psi) is obtained on the proportioning valve inlet
gauge. Then based on the type of brake system the vehicle is equipped with and the pressure
specification shown on the following table, compare the pressure reading on the outlet gauge to the
specification. If outlet pressure at the proportioning valve is not within specification when required
inlet pressure is obtained, replace the proportioning valve.
8. Repeat steps 2 through 7 for the other proportioning valve of the assembly.
CAUTION: When mounting the original or a replacement proportion valve on the frame rail of the
vehicle install the mounting bolts in only the two forward holes of the mounting bracket.
Proportioning valve split point pressure conversion is 1 bar is equal to 14.5 psi.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Testing and Inspection > With Antilock Brakes > Page 4315
Brake Proportioning/Combination Valve: Testing and Inspection Without Antilock Brakes
CAUTION: The use of aftermarket load leveling or load capacity increasing devices on this vehicle
are prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height
sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes.
This inappropriate reduction in hydraulic pressure potentially could result in increased stopping
distance of the vehicle.
When a premature rear wheel skid is obtained on a brake application, it may be an indication that
the hydraulic pressure to the rear brakes is above the specified output from the proportioning valve.
This condition indicates a possible malfunction of the height sensing proportioning valve, which will
require testing to verify that it is properly controlling the hydraulic pressure allowed to the rear
brakes. Premature rear wheel skid may also be caused by an incorrectly adjusted proportioning
valve actuator assembly, or contaminated front or rear brake linings.
Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also,
ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify
that the brakes shoe assemblies on a vehicle being tested, are either Original Equipment
Manufacturers (OEM), or original replacement brake shoe assemblies meeting the OEM lining
material specification. The vehicles brake system is not balanced for after market brake shoe
assembly lining material.
If both front and rear brakes check OK, proceed to verify that the actuator assembly for the height
sensing proportioning valve is adjusted correctly. If the proportioning valve is adjusted correctly,
proceed with the test procedure for the height sensing proportioning valve as follows:
Actuator Assembly Adjustment Nut
1. Remove the actuator assembly adjustment nut. Remove the actuator assembly from the lever on
the height sensing proportioning valve.
Brake Tube Connections To Proportioning Valve
2. Remove the chassis brake tube coming from the junction block from the front of the height
sensing proportioning valve. Remove the chassis brake
tube going to the rear brakes from the back of the height sensing proportioning valve.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Testing and Inspection > With Antilock Brakes > Page 4316
Proportioning Valve Test Fitting Installation
Pressure Gauges Installed On Pressure Test Fittings
3. Install the required fittings from Pressure Test Fittings, Special Tool 6833 into the inlet port of the
proportioning valve assembly, from which the
chassis brake line was removed. Install the removed chassis brake line into the Pressure Test
Fitting. Install the required fitting from Pressure Test Fittings, Special Tool 6833 into the required
outlet port of the proportioning valve. Install the required fitting from Pressure Test Fittings, Special
Tool 6833 into the required outlet port of the proportioning valve. Then install the removed chassis
brake line into the Pressure Test Fitting.
4. Install a pressure gauge from Gauge Set, Special Tool C-4007-A into each pressure test fitting.
Bleed air out of hose from pressure test fittings to
pressure gauges, at the pressure gauges. Then bleed air out of the brake line being tested, at that
rear wheel cylinder.
5. With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000
psi) is obtained on the proportioning valve inlet
gauge. Then based on the type of brake system the vehicle is equipped with and the pressure
specification shown on the following table, compare the pressure reading on the outlet gauge to the
specification. If outlet pressure at the proportioning valve is not within specification when required
inlet pressure is obtained, replace the proportioning valve.
6. Remove the pressure test fittings and pressure pauses from the proportioning valve. 7. Install
the chassis brake lines in the correct ports of the proportioning valve. 8. Install the pressure test
fittings and pressure gauges in the opposite inlet and outlet port of the height sensing proportioning
valve. Repeat steps 4
and 5 for the other proportioning valve.
9. Remove the pressure test fittings and pressure gauges from the proportioning valve.
10. Install the chassis brake lines in the correct ports of the proportioning valve.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Testing and Inspection > With Antilock Brakes > Page 4317
11. Install the actuator on the height sensing proportioning valve. Adjust the proportioning valve
actuator. 12. Bleed both rear hydraulic circuits at the rear brakes. 13. Road test vehicle.
Proportioning valve split point pressure conversion is 1 bar is equal to 14.5 psi.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Service and Repair > With Antilock Brakes
Brake Proportioning/Combination Valve: Service and Repair With Antilock Brakes
The actual proportioning valves of the proportioning valve assembly are not serviceable or
replaceable. If a proportioning valve of the proportioning valve assembly is not functioning properly,
the fixed proportioning valve must be replaced as an assembly.
REMOVE
1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the proportioning valve.
2. Raise vehicle on jackstands or centered on a hoist.
CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve
and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from
entering the proportioning valve or the brake tubes.
Chassis Brake Tubes At Proportioning Valve
3. Remove the 4 chassis brake lines from the inlet and outlet ports of the proportioning valve.
Proportioning Valve Attachment To Vehicle
4. Remove the bolts attaching the proportioning valve bracket to the frame rail of the vehicle.
Remove the fixed proportioning valve assembly from
the vehicle.
INSTALL
CAUTION: When mounting the original or a replacement proportioning valve on the frame rail of
the vehicle install the mounting bolts in only the two forward holes of the mounting bracket.
1. Install proportioning valve assembly on the frame rail of the vehicle. Install the proportioning
valve assembly attaching bolts. Tighten the attaching
bolts to a torque of 14 Nm (125 inch lbs.).
2. Install the 4 chassis brake lines into the inlet and outlet ports of the proportioning valve
assembly. Tighten all 4 line nuts to a torque of 16 Nm
(142 inch lbs.).
3. Bleed the brake system thoroughly enough to ensure that all air has been expelled from the
hydraulic system. See Brake Bleeding for the proper
bleeding procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Service and Repair > With Antilock Brakes > Page 4320
4. Lower the vehicle to the ground. 5. Road test the vehicle to verify proper operation of the
vehicle's brake system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Service and Repair > With Antilock Brakes > Page 4321
Brake Proportioning/Combination Valve: Service and Repair Without Antilock Brakes
The components of the proportioning valve assembly are not serviceable or replaceable. If a
component of the proportioning valve assembly is not functioning properly, the proportioning valve
must be replaced as an assembly.
REMOVAL
1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the proportioning valve.
2. Raise vehicle on jackstands or centered on a hoist.
CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve
and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from
entering the proportioning valve or the brake tubes.
Chassis Brake Tubes At Proportioning Valve
3. Remove the 4 chassis brake tubes from the inlet and outlet ports of the proportioning valve.
Proportioning Valve Mounting
4. Remove the 2 bolts attaching the proportioning valve to the proportioning valve mounting
bracket. Remove the proportioning valve from the
mounting bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Service and Repair > With Antilock Brakes > Page 4322
Actuator Attachment To Proportioning Valve
5. Remove the hooked end of the proportioning valve actuator from the isolator bushing on the
lever of the height proportioning valve.
INSTALLATION
1. Install the hooked end of the actuator on the proportioning valve lever. Be sure isolator bushing
on lever of proportioning valve is fully seated in
hook of actuator.
NOTE: When installing height sensing proportioning valve on mounting bracket be sure
proportioning valve shield is installed between the proportioning valve and the mounting bracket.
2. Install height sensing proportioning valve on mounting bracket. Install the proportioning valve
attaching bolts. Tighten the attaching bolts to a
torque of 23 Nm (200 inch lbs.).
3. Install the 4 chassis brake lines into the inlet and outlet ports of the proportioning valve. Tighten
all 4 line nuts to a torque of 16 Nm (142 inch
lbs.).
4. Adjust the proportioning valve actuator. 5. Bleed the brake system thoroughly to ensure that all
air has been expelled from the hydraulic system. See Brake Bleeding for the proper bleeding
procedure.
6. Lower the vehicle to the ground. 7. Road test the vehicle to verify proper operation of the
vehicles brake system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Mounting Bracket To Suspension Cradle Bolts
.................................................................................................................................. 28 Nm (250 inch
lbs.) To Mounting Bracket Isolator Attaching Bolts
..................................................................................................................................... 11 Nm (97
inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 4326
Hydraulic Control Unit
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 4327
Hydraulic Control Assembly - Antilock Brakes: Description and Operation
Teves Mark 20 ICU
The Hydraulic Control Unit (HCU) is mounted to the CAB as part of the ICU. The ICU is located on
the driver's side of the front suspension cradle under the vehicle. The HCU controls the flow of
brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on
the HCU to supply build pressure to the brakes during an ABS stop.
The HCU on a vehicle equipped with ABS and traction control has a valve block housing that is
approximately 1 inch longer on the low pressure fluid accumulators side than a HCU on a vehicle
that is equipped with only ABS.
VALVES AND SOLENOIDS
The valve block contains four inlet valves and four outlet valves. The inlet valves are spring-loaded
in the open position and the outlet valves are spring loaded in the closed position during normal
braking. The fluid is allowed to flow from the master cylinder to the wheel brakes.
During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet
valve closes preventing further pressure increase and the outlet valve opens to provide a path from
the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from
the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer
slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure.
On vehicles with traction control, there is an extra set of valves and solenoids. The ASR valves,
mounted in the HCU valve block, are normally in the open position and close only when the traction
control is applied.
These isolator valves are used to isolate the rear (non-driving) wheels of the vehicle from the
hydraulic pressure that the HCU pump/motor is sending to the front (driving) wheels when traction
control is being applied. The rear brakes need to be isolated from the master cylinder when traction
control is being applied so the rear wheels do not drag. For more information, see Traction Control
System.
BRAKE FLUID ACCUMULATORS
There are two fluid accumulators in the HCU-one for the primary hydraulic circuit and one for the
secondary hydraulic circuit. Each hydraulic circuit uses a 5 cc accumulator.
The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during
an ABS cycle. This stored fluid is used by the pump/motor to provide build pressure for the brake
hydraulic system. When the antilock stop is complete, the accumulators are drained by the
pump/motor.
On ABS-only vehicles, there is a mini-accumulator on the secondary hydraulic circuit that protects
the master cylinder seals during an ABS stop, and there is a noise dampening chamber on the
primary circuit.
On ABS with traction control vehicles, there are two noise dampening chambers in the HCU.
PUMP/MOTOR
There are two pump assemblies in the HCU-one for the primary hydraulic circuit and one for the
secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type
motor is integral to the HCU and is controlled by the CAB.
The pump/motor provides the extra amount of brake fluid needed during antilock braking. Brake
fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The
pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In
operation, one piston draws fluid from the accumulators, and the opposing piston pumps fluid to the
master cylinder circuits. When the antilock stop is complete, the pump/motor drains the
accumulators.
The CAB may turn on the pump/motor when an antilock stop is detected. The pump/motor
continues to run during the antilock stop and is turned off
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Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 4328
after the stop is complete. Under some conditions, the pump/motor runs to drain the accumulators
during the next drive-off.
The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU)
Replacement
Removal
NOTE: Before proceeding, review all SERVICE WARNINGS AND CAUTIONS in Service
Precautions.
1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake
pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This
will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the HCU.
3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type
hoist.
CAB 25 Way Connector
4. Remove the routing clip attaching the ICU wiring harness to the ICU mounting bracket.
CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector
when disconnected.
Unlocked 25 Way CAB Connector
5. Remove the 25 way connector from the CAB. The 25 way connector is removed from the CAB
using the following procedure. Grasp the lock on
the 25 way connector and pull it as far out as possible. This will raise and unlock the 25 way
connector from the socket on the CAB.
CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned.
This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake
tubes.
6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only
a solvent such as Mopar Brake Parts Cleaner or
an equivalent to clean the HCU.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4331
Brake Tube Connections To HCU
7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU.
ICU To Suspension Cradle Mounting Bolts
8. Remove the 3 bolts attaching the ICU mounting bracket to the front suspension crossmember. 9.
Remove ICU and the mounting bracket as a unit from the vehicle.
ICU Mounting Bolts
10. Remove the 3 bolts mounting the ICU to the mounting bracket. Separate the ICU from the
mounting bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4332
11. Refer to Overhaul for the procedure on separating and attaching the CAB to the HCU.
Installation
1. Install the ICU on the mounting bracket. Install the 3 bolts attaching the ICU to the mounting
bracket. Tighten the 3 mounting bolts to a torque of
11 Nm (97 inch lbs.).
CAUTION: The ICU mounting bracket to front suspension cradle mounting bolts have a unique
corrosion protection coating and a special aluminum washer. For this reason, only the original, or
original equipment Mopar replacement bolts can be used to mount the ICU bracket to the front
suspension crossmember.
2. Install the ICU and its mounting bracket as an assembly on the front suspension crossmember.
Install the 3 bolts attaching the ICU bracket to the
crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.).
Brake Tube Connections To HCU
CAUTION: ^
Because of the flexible section in the primary and secondary brake tubes, and the brake tubes
between the HCU and the proportioning valve, the brake tubes must be held in proper orientation
when tightened and torqued. These tubes must not contact each other or other vehicle components
when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are
reinstalled on the brake tubes.
^ When installing the chassis brake tubes on the HCU valve block, they must be located correctly
in the valve block to ensure proper ABS operation. Refer to the image for the correct chassis brake
tube locations.
NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the
ICU mounting bracket.
3. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as
shown. Tighten the tube nuts to a torque of 17 Nm
(145 inch lbs.).
NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in
the connector.
4. Install the 25 way connector on the CAB using the following procedure. Position the 25 way
connector in the socket of the CAB and carefully
push it down as far as possible. When connector is fully seated by hand into the CAB socket, push
in the connector lock. This will pull the connector into the socket of the CAB and lock it in the
installed position.
NOTE: The CAB wiring harness must be clipped to the ICU mounting bracket. This will ensure the
wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle.
5. Clip the cab wiring harness to the ICU mounting bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4333
Brake Tube Routing Clips
6. Install the routing clips on the brake tubes. 7. Lower the vehicle. 8. Connect negative cable back
on negative post of the battery. 9. Bleed the base and ABS hydraulic systems.
10. Road test vehicle to ensure proper operation of the base and antilock brake systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4334
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU)
Overhaul
REMOVAL
NOTE: To replace the Hydraulic Control Unit (HCU) or the Controller Antilock Brake (CAB) on this
vehicle, the entire Integrated Control Unit (ICU) needs to be removed from the vehicle. The CAB
can then be separated from the HCU. Do not attempt to replace the CAB with the ICU mounted in
the vehicle.
1. Remove the ICU from the vehicle.
Pump/Motor To CAB Wiring Harness
2. Disconnect the pump/motor wiring harness from the CAB.
CAB Attaching Bolts
3. Remove the 4 bolts attaching the CAB to the HCU.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Replacement > Page 4335
Remove/Install CAB
4. Remove the CAB from the HCU.
INSTALLATION
1. Install the CAB on the HCU. 2. Install the 4 bolts mounting the CAB to the HCU. Tighten the CAB
mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the
CAB. 4. Install the ICU in the vehicle. 5. Bleed the base and ABS hydraulic systems. 6. Road test
the vehicle to ensure proper operation of the base brakes and ABS.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block >
Component Information > Specifications
Hydraulic System Junction Block: Specifications
Junction Block Mounting Bolts
...........................................................................................................................................................
28 Nm (250 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Adjustments
Load Compensator: Adjustments
PROPORTIONING VALVE (HEIGHT SENSING)
Proportioning valve adjustment will be required if there is a complaint of premature rear wheel
lockup and the front and rear brake shoe linings checked OK during inspection, the height sensing
proportioning valve required replacement, or there is a complaint of excessive pedal effort and the
vacuum booster and brake pedal checked OK. Make sure the proportioning valve and the mounting
bracket are firmly attached to the vehicle. Then, proceed with the following procedure to perform
the adjustment of the vehicle. 1. Raise vehicle. Vehicle is to be raised and supported on jackstands
or with a frame contact type hoist so the rear suspension of the vehicle is
hanging free.
2. Remove rear wheels/tires. 3. Using an appropriate jack, support the rear axle prior to the
removal of the track bar and shock absorber bolts from the rear axle. 4. Unbolt the track bar from
the rear axle. 5. Unbolt both shock absorbers from the rear axle. 6. Loosen (do not remove) both of
the leaf spring to front spring hanger pivot bolts.
NOTE: When lowering the rear axle be sure that the leaf springs do not come in contact with the
hoist limiting the downward movement of the axle. If this occurs an improper adjustment of the
actuator may result.
7. Lower the rear axle so it is at its farthest point of downward movement.
8. Loosen the adjustment nut on the actuator. 9. Be sure the hooked end of the actuator is correctly
(fully) seated in the clip on the proportioning valve lever and that the clip is correctly
positioned on the lever of the proportioning valve.
10. Pull the housing of the proportioning valve actuator toward the spring hanger until the lever on
the proportioning valve bottoms on the body of the
proportioning valve. Hold the proportioning valve actuator in this position while tightening the
adjustment nut to a torque of 5 Nm (45 inch lbs.). Proportioning valve adjustment is now complete.
11. Install shock absorbers and track bar on rear axle. Do not tighten the mounting bolts of the
loosened suspension components at this time. 12. Install the wheel/tires. 13. Lower the vehicle to
the ground. Be sure that the suspension is supporting the full weight of the vehicle. 14. Tighten the
spring to front hanger pivot bolts to a torque of 156 Nm (115 ft. lbs.). 15. Tighten the shock
absorber mounting bolts to a torque of 101 Nm (75 ft. lbs.). 16. Tighten the track bar mounting bolt
to a torque of 95 Nm (70 ft. lbs.). 17. Road test vehicle to ensure that the premature rear wheel
lockup condition has been corrected.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > With Antilock Brakes
Brake Master Cylinder: Specifications With Antilock Brakes
DIMENSIONS:
Bore/Stroke
.................................................................................................................................................... 23.8
mm x 36 mm (0.937 inch x 1.47 inch) Displacement Split ...................................................................
................................................................................................................................. 50/50
With ABS Only: Primary Fluid Outlet Ports ..........................................................................................
........................................................................................... 7/16-24 Secondary Fluid Outlet Ports .....
..............................................................................................................................................................
.............. 7/16-24
With ABS With Traction Control: Primary Fluid Outlet Ports ...............................................................
..................................................................................................................... M12 x 1 Secondary Fluid
Outlet Ports ..........................................................................................................................................
...................................... M12 x 1
TIGHTENING TORQUES:
Mounting Nuts .....................................................................................................................................
............................................ 25 Nm (225 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > With Antilock Brakes > Page 4346
Brake Master Cylinder: Specifications Without Antilock Brakes
DIMENSIONS:
Bore/Stroke
.................................................................................................................................................... 23.8
mm x 36 mm (0.937 inch x 1.47 inch) Displacement Split ...................................................................
................................................................................................................................. 50/50 Primary
Fluid Outlet Ports .................................................................................................................................
.................................................... 7/16-24 Secondary Fluid Outlet Ports ............................................
..................................................................................................................................... 7/16-24
TIGHTENING TORQUES:
Mounting Nuts .....................................................................................................................................
............................................ 25 Nm (225 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > Page 4347
Brake Master Cylinder: Description and Operation
Master Cylinder Assembly
The master cylinder consists of the following components: The body of the master cylinder is an
anodized aluminum casting. It has a machined bore to accept the master cylinder pistons and
threaded ports with seats for the hydraulic brake line connections. The brake fluid reservoir of the
master cylinder assembly is made of a see through polypropylene type plastic. A low fluid switch is
also part of the reservoir assembly.
This vehicle uses 3 different master cylinders. Master cylinder usage depends on what type of
brake system the vehicle is equipped with. If a vehicle is not equipped with antilock brakes, or is
equipped with antilock brakes without traction control, a conventional compensating port master
cylinder is used. If a vehicle is equipped with antilock brakes with traction control, a dual center port
master cylinder is used.
The third master cylinder used on this vehicle is unique to vehicles equipped with four wheel disc
brakes. The master cylinder used for this brake application has a different bore diameter and stroke
than the master cylinder used for the other available brake applications.
The master cylinders used on front wheel drive applications (non four wheel disc brake vehicles)
have a master cylinder piston bore diameter of 23.8 mm. The master cylinder used on the all wheel
drive applications (four wheel disc brake vehicles) have a master cylinder piston bore diameter of
25.4 mm. When replacing a master cylinder, be sure to use the correct master cylinder for the type
of brake system the vehicle is equipped with.
The master cylinder is not a repairable component and must be replaced if diagnosed to be
functioning improperly.
CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface from the
bore.
The master cylinder primary outlet port supplies hydraulic pressure to the right front and left rear
brakes. The secondary outlet port supplies hydraulic pressure to the left front and right rear brakes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding
Brake Master Cylinder: Service and Repair Master Cylinder Bleeding
Bench Bleeding
CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting
flange, do not clamp on primary piston, seal, or body of master cylinder.
Master Cylinder Mounted In Vise
1. Clamp the master cylinder in a vise using only the mounting flange.
NOTE: Two different size bleeding tubes are used depending on which type of master cylinder the
vehicle is equipped with. Vehicles equipped with traction control use a center port master cylinder
with a 6 millimeter diameter brake tube. Vehicles not equipped with traction control use a
compensating port master cylinder using a standard 3/16 inch diameter brake tube. Be sure the
correct size bleeding tubes are used when bleeding the master cylinder.
Bleed Tubes Installed On Master Cylinder
2. Install the Bleeding Tubes, Special Tool 6920, for a non-traction control master cylinder or
Special Tool 8129 for a traction control master
cylinder on the master cylinder. Position bleeding tubes so the outlets of bleeding tubes will be
below surface of brake fluid when reservoir is filled to its proper level.
3. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an
equivalent. 4. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to
released position. Repeat several times until all air bubbles are
expelled from master cylinder.
5. Remove bleeding tubes from master cylinder outlet ports, and then plug outlet ports and install
fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install the filler cap from the master
cylinder filler neck, on the master cylinder fluid reservoir. 8. Install the master cylinder assembly on
the power brake vacuum booster.
NOTE: It is not necessary to bleed the ABS Hydraulic Control Unit (HCU) after replacing the master
cylinder, but the base brake hydraulic
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4350
system must be bled to ensure no air is entered the hydraulic system when the master cylinder was
removed.
Manual Bleeding
NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper.
- To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be
correctly adjusted. Prior to the manual bleeding of the brake hydraulic system, correctly adjust the
rear brakes.
- The following wheel sequence should be used when bleeding the brake hydraulic system. The
use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic
system.
^ Left Rear Wheel
^ Right Front Wheel
^ Right Rear Wheel
^ Left Front Wheel
1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened.
2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens
the brake pedal will drop all the way to the floor.
3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four
or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount
of fluid to expel
all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder,
so it stays at a proper level so air will not enter the brake system through the master cylinder.
5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4351
Brake Master Cylinder: Service and Repair Master Cylinder Replacement
CAUTION: Different types of master cylinders are used on this vehicle. Vehicles equipped with
traction control use a center port master cylinder. Vehicles not equipped with traction control use a
compensating port master cylinder. Be sure to verify if the vehicle is equipped with traction control
and that the correct replacement master cylinder is used. Also, vehicles that are equipped with four
wheel disc brakes have a master with a different size piston bore than the other master cylinders. If
a new master cylinder is being installed, be sure the correct master cylinder is used for the type of
brake system the vehicle is equipped with.
REMOVE
CAUTION: Vacuum in the power brake booster must be pumped down (removed) before removing
master cylinder from power brake booster. This is necessary to prevent the power brake booster
from sucking in any contamination as the master cylinder is removed. This can be done simply by
pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is
achieved.
1. With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes).
CAUTION: Before removing the master cylinder filler tube from the brake fluid reservoir, the filler
tube, brake fluid reservoir and master cylinder must be thoroughly cleaned. This must be done to
prevent dirt particles from falling into the brake fluid reservoir and entering the brakes hydraulic
system.
2. Thoroughly clean all surfaces of the filler neck, brake fluid reservoir, and master cylinder. Use
only a solvent such as Mopar Brake Parts Cleaner
or an equivalent.
Master Cylinder Filler Tube Removal
3. Remove master cylinder filler tube from brake fluid reservoir by pushing down and rotating. Then
remove the cap from the removed filler tube and
install it on the master cylinder reservoir.
Master Cylinder Assembly
4. Remove vehicle wiring harness connector, from the brake fluid level sensor, in master cylinder
brake fluid reservoir.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4352
Primary/Secondary Brake Tubes At Master Cylinder
5. Disconnect the primary and secondary brake tubes from the master cylinder housing. Install
sealing plugs in the open brake tube outlets on master
cylinder assembly.
CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt
particles from falling into the lower brake vacuum booster.
6. Clean the area where the master cylinder assembly attaches to the power brake booster. Use
only a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
Master Cylinder Mounting To Vacuum Booster
7. Remove the 2 nuts attaching the master cylinder assembly to the brake vacuum booster. 8. Slide
master cylinder assembly straight out of the power brake vacuum booster.
CAUTION: The master cylinder is used to create the seal for holding vacuum in the power brake
vacuum booster. The vacuum seal/boot on the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake vacuum booster.
9. Remove the vacuum seal located on the mounting flange of the master cylinder. The vacuum
seal is removed from the master cylinder by carefully
pulling it away from the master cylinder. Do not attempt to pry the seal off the master cylinder by
inserting a sharp tool between seal and master cylinder casting.
Bleeding Master Cylinder
CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting
flange, do not clamp on primary piston, seal or body of master cylinder.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4353
Master Cylinder Mounted In Vise
1. Clamp the master cylinder in a vise using only the mounting flange.
NOTE: Two different size bleeding tubes are used depending on which type of master cylinder the
vehicle is equipped with. Vehicles equipped with traction control use a center port master cylinder
with a larger diameter brake tube. Vehicles not equipped with traction control use a compensating
port master cylinder using a standard 3/16 inch diameter brake tube. Be sure the correct size
bleeding tubes are used when bleeding the master cylinder.
Bleed Tubes Installed On Master Cylinder
2. Install the Bleeding Tubes, Special Tool 6920 for a non-traction control master cylinder or
Special Wool 8129 for a traction control master
cylinder on the master cylinder. Position bleeding tubes so the outlets of bleeding tubes will be
below surface of brake fluid when reservoir is filled to its proper level.
3. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an
Equivalent. 4. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to
released position. Repeat several times until all air bubbles are
expelled from master cylinder.
5. Remove bleeding tubes from master cylinder outlet ports, and then plug outlet ports and install
fill cap on reservoir. 6. Remove master cylinder from vise.
NOTE: It is not necessary to bleed the ABS Hydraulic Control Unit (HCU) after replacing the master
cylinder. But, the base brake hydraulic system must be bled to ensure no air is entered the
hydraulic system when the master cylinder was removed.
INSTALL
CAUTION: When replacing the master cylinder on a vehicle, a NEW vacuum seal MUST be
installed on the master cylinder. Use only procedure detailed below for installing the vacuum seal
onto the master cylinder.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4354
Vacuum Seal Installed On Master Cylinder
1. Install a NEW vacuum seal on master cylinder making sure seal sits squarely in groove of
master cylinder casting. 2. Position master cylinder on studs of power brake unit, aligning push rod
on power brake vacuum booster with master cylinder push rod. 3. Install the 2 master cylinder to
power brake unit mounting nuts. Then tighten both mounting nuts to a torque of 25 Nm (225 inch
lbs.).
CAUTION: When installing the primary and secondary brake tubes on master cylinder, be sure
brake tubes do not contact any other components within the vehicle and that there is slack in the
flexible sections of the tubes. This is required due to the movement between the ABS hydraulic
control module (HCU) and the master cylinder, when the vehicle is in motion.
4. Connect the primary and secondary brake tubes to master cylinder primary and secondary ports.
Brake tubes must be held securely when tightened
to control orientation of flex section. Then fully tighten the tube nuts to a torque of 17 Nm (145 inch
lbs.).
5. Install the vehicle wiring harness connector, on the brake fluid level sensor in the master cylinder
brake fluid reservoir. 6. Install filler tube into the master cylinder fluid reservoir.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4355
Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement
1. Clean master cylinder housing and brake fluid reservoir. Use only a solvent such as Mopar
Brake Parts Cleaner or an equivalent. 2. Remove the filler tube and brake fluid reservoir cap. Using
a syringe or equivalent type tool empty as much brake fluid as possible from the
reservoir.
CAUTION: When removing fluid reservoir from the master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master cylinder housing.
3. Remove the master cylinder assembly from the power brake vacuum booster.
Master Cylinder Mounted In Vise
4. Mount the master cylinder in a vise using the master cylinder mounting flange.
Fluid Reservoir Retaining Pins
5. Using correct size pin punch, remove the 2 retaining pins between the fluid reservoir and master
cylinder housing. Rock the brake fluid reservoir
from side to side while pulling up to remove it from the seal grommets in master cylinder housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4356
Master Cylinder To Fluid Reservoir Seal Grommets
6. Remove the 2 master cylinder housing to brake fluid reservoir seal grommets. 7. Install new
master cylinder housing to brake fluid reservoir sealing grommets in master cylinder housing. 8.
Lubricate reservoir mounting area with fresh clean brake fluid. Place reservoir in position over
sealing grommets. Seat reservoir into sealing
grommets using a rocking motion while firmly pressing down on fluid reservoir.
9. Be sure fluid reservoir is positioned properly on master cylinder. Bottom of fluid reservoir is to be
touching the top of both sealing grommets when
properly installed on master cylinder housing.
10. Install the 2 fluid reservoir to master cylinder retaining pins. 11. Install the master cylinder
assembly on the power brake vacuum booster. 12. Install filler tube on the fluid reservoir. Fill fluid
reservoir to its proper level as indicated on the outboard side of the fluid reservoir. Be careful not
to overfill the fluid reservoir, fluid is not intended to be stored in the filler tube. Install cap on fluid
reservoir filler tube.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4357
Brake Master Cylinder: Service and Repair Fluid Reservoir Fill Tube Replacement
The master cylinder fluid reservoir filler neck is removable from the master cylinder fluid reservoir.
The filler neck if required, can be replaced as a separate component of the fluid reservoir.
The filler neck is removed and installed using the following procedure.
REMOVE
1. Check brake fluid level in master cylinder fluid reservoir to be sure brake fluid is not in the filler
neck. If brake fluid is in filler neck, lower fluid
level before removing filler neck from fluid reservoir.
Master Cylinder Fluid Reservoir Filler Neck
2. Grasp filler neck at cap end and push straight down. This will cause the filler neck to pop out of
the fluid reservoir.
INSTALL
1. Wet the O-ring on the reservoir end of the filler neck with fresh clean brake fluid. 2. Position the
filler neck in the opening on the fluid reservoir. Ensure tab on filler neck is in the groove on the front
of the fluid reservoir. 3. Push down while slightly rocking filler neck until filler neck snaps into the
fluid reservoir opening. 4. Install cap on filler neck. 5. Check and/or add brake fluid in reservoir to
ensure it is at the correct level.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 4358
Brake Master Cylinder: Service and Repair Master Cylinder to Power Brake Booster Vacuum Seal
1. Remove the master cylinder from the power brake vacuum booster. 2. Using a soft tool such as
a trim stick, remove the vacuum seal from the master cylinder mounting flange. 3. Using Mopar
Brake Parts Cleaner or an equivalent, thoroughly clean end of master cylinder housing and master
cylinder push rod.
Vacuum Seal Installed On Master Cylinder
4. Install new master cylinder to power brake booster vacuum seal on master cylinder. When
installing new vacuum seal, be sure it is squarely seated
against master cylinder mounting flange and in groove of push rod.
5. Bleed the master cylinder assembly prior to installing it on the power brake vacuum booster. 6.
Install master cylinder assembly on the power brake vacuum booster. 7. Road test vehicle to
ensure proper operation of the vehicle's power brake system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications
Wheel Cylinder: Specifications
Diameter 3/4 in
To Support Plate Mounting Bolts 75 in.lb
Bleeder Screw 80 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation
Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation
REMOVE
1. In case of a leak, remove brake shoes. Replace if soaked with grease or brake fluid.
2. Disconnect the rear brake hydraulic tube from the wheel cylinder. 3. Remove the rear wheel
cylinder attaching bolts. Pull wheel cylinder assembly off the brake support plate.
INSTALL
1. Apply Mopar Gasket In-A-Tube or equivalent sealant around wheel cylinder mounting surface in
brake support plate. 2. Install wheel cylinder onto brake support, and tighten the wheel cylinder to
brake support plate attaching bolts to 8 Nm (75 inch lbs.). 3. Attach hydraulic brake tube to wheel
cylinder, and tighten tube to wheel cylinder fitting to 16 Nm (142 inch lbs.). 4. Install brake shoes on
support plate. 5. Install rear brake drum onto rear hub. Install rear wheel and tire assembly, tighten
wheel stud nuts to 129 Nm (95 ft. lbs.). 6. Adjust the rear brakes. 7. Bleed the entire brake system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4364
Wheel Cylinder: Service and Repair Cleaning and Inspection
With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak.
Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel
cylinders should be completely cleaned, inspected, and new parts installed.
If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake
shoes must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 4365
Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul
DISASSEMBLE
To disassemble the wheel cylinders, proceed as follows:
Fig 3 Wheel Cylinder
1. Pry boots away from cylinders and remove. 2. Press in on one piston to force out opposite
piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston
that
remain in the wheel cylinder.
3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol, (DO NOT USE ANY
PETROLEUM BASE SOLVENTS) clean
thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and
pitting. (Do not use a rag as lint from the rag will stick to bore surfaces.)
4. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. Cylinder
walls that have light scratches, or show signs of
corrosion, can usually be cleaned with crocus cloth, using a circular motion. Black stains on the
cylinder walls are caused by piston cups and will not impair operation of cylinder.
ASSEMBLE
Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. If
the boots are deteriorated, cracked or do not fit tightly on the pistons or the cylinder casting, install
new boots.
1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the
wheel cylinder cups with only Mopar Protect A-Cup Lubricant. 3. Install expansion spring with cup
expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other.
4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of
each cup, already installed. 5. Install a boot over each end of cylinder. Be careful not to damage
boot during installation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component
Information > Technical Service Bulletins > Rear Wheel Park Brake Actuator/Lever - Service
Parking Brake Actuator: Technical Service Bulletins Rear Wheel Park Brake Actuator/Lever Service
NUMBER: 05-09-99
GROUP: Brakes
DATE: Nov. 5, 1999
SUBJECT: Rear Wheel Park Brake Actuator/Lever Service
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager 1997 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REAR WHEEL DISC BRAKES
(SALES CODE BRE OR BR3).
DISCUSSION: Whenever servicing the park brake actuator/lever of rear wheel disc brake equipped
vehicles, DO NOT attempt to repair it. The park brake actuator/lever must be replaced with p/n
04882584AA whenever service is required.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Adjustments
Parking Brake Cable: Adjustments
The park brake cables on this vehicle have an automatic self adjuster built into the park brake
pedal mechanism. When the foot operated park brake pedal is in its released (upward most)
position, a clock spring automatically adjusts the park brake cables. The park brake cables are
adjusted (tensioned) just enough to remove all the slack from the cables. The automatic adjuster
system will not over adjust the cables causing rear brake drag.
Due to the automatic adjust feature of the park brake pedal, adjustment of the parking brake cables
on these vehicles relies on proper drum brake and park brake shoe adjustment.
When the park brake pedal is applied the self adjuster is by-passed and the pedal operates
normally to engage the park brakes.
When a service procedure needs to be performed on the park brake pedal or the park brake
cables, the automatic self adjuster can be manually locked out by the service technician.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement
Parking Brake Cable: Service and Repair Front Cable Replacement
REMOVAL
1. Raise vehicle on jackstands or centered on a hoist. 2. Manually release the automatic
self-adjusting mechanism tension of the parking brake lever (pedal) assembly.
Parking Brake Cable Attachment To Equalizer
3. Remove the intermediate and left rear park brake cable from the park brake cable equalizer.
Front Park Brake Cable Attachment To Body
4. Remove the front park cable housing retainer from body outrigger bracket. Cable is removable
by sliding a 14 mm box wrench over cable retainer
and compressing the three retaining fingers. Alternate method is to use an aircraft type hose clamp
and screwdriver.
5. Lower vehicle. 6. Remove the left front door sill molding. 7. Remove the left front kick panel for
access to the park brake cable and park brake pedal assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 4376
Front Park Brake Cable At Floor Pan
8. Lift floor mat for access to park brake cable and floor pan. Pull the seal and the park brake cable
out of the floor pan of vehicle. 9. Pull parking brake cable strand end forward and disconnect button
from clevis. Tap cable housing end fitting out of pedal assembly bracket.
10. Remove cable retainer from the parking brake lever (pedal) assembly bracket. 11. Pull front
parking brake cable assembly out of vehicle through hole in floor pan.
INSTALLATION
1. Pass front parking brake cable assembly through hole in floor pan from the inside of the vehicle.
2. Pass cable strand button through the hole in the lever (pedal) assembly bracket. 3. Install cable
retainer onto the park brake cable and then install cable retainer into pedal assembly bracket. 4.
Install the end of the park brake cable into the retainer previously installed into the park brake pedal
bracket. 5. Install cable strand button into the clevis on the park brake pedal mechanism. 6. Install
the front park brake cable floor pan seal into hole in floor pan. Seal is to be installed so the flange
on the seal is flush with the floor pan.
Fold carpeting back down on floor.
7. Raise vehicle. 8. Insert brake cable and housing into body outrigger bracket making certain that
housing retainer fingers lock the housing firmly into place. 9. Manually reset the automatic
self-adjusting mechanism tension of the parking brake lever (pedal) assembly.
10. Assemble the park brake cables onto the park brake cable equalizer. 11. Lower vehicle and
apply the park brake pedal 1 time. This will seat the parking brake cables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 4377
Parking Brake Cable: Service and Repair Intermediate Cable Replacement
REMOVAL
1. Raise vehicle on jackstands or centered on a hoist. 2. Manually lock out the automatic
self-adjusting mechanism tension of the parking brake lever (pedal) assembly. Once the cable is
released from the
equalizer, do not remove the locking pliers until reinstallation of the cable is complete.
Parking Brake Cable Attachment To Equalizer
3. Remove the intermediate parking brake cable from the parking brake cable equalizer. 4.
Remove the locking nut securing the intermediate cable housing to the side bracket on the frame
rail.
Intermediate Cable Attachment To Right Rear Cable
5. Remove the intermediate parking brake cable from the cable connector attaching it to the right
rear parking brake cable. Remove the locking nut
securing the intermediate cable housing to the side bracket on the frame rail.
6. Remove the intermediate parking brake cable from the side brackets and vehicle.
INSTALLATION
1. Install the ends of the park brake cables through the frame rails and into the side brackets. 2.
Install the locking nuts at each end of the cable and securely tighten. 3. Install the intermediate
parking brake cable on the cable connector at the right rear parking brake cable. 4. Install the
intermediate park brake cable on the cable equalizer. 5. Remove the locking pliers from the front
park brake cable. This will activate the automatic adjuster and correctly adjust the parking brake
cables. 6. Install and position the foam collar on the parking brake cable to prevent it from rattling
against the vehicle's floor. 7. Lower the vehicle and apply the park brake pedal 1 time, this will seat
the park brake cables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 4378
Parking Brake Cable: Service and Repair Left Rear Cable Replacement
REMOVAL
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear tire and wheel assembly. 3.
Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake
cable.
Locking Out Automatic Adjuster
4. Create slack in rear park brake cables by locking out the automatic adjuster as described here.
Grasp an exposed section of front park brake cable
near the equalizer and pull down on it. Then install a pair of locking pliers on the cable just
rearward of the second body outrigger bracket.
Parking Brake Cable Attachment To Equalizer
5. Disconnect the left rear parking brake cable from the parking brake cable equalizer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 4379
Park Brake Cable Removal From Body Bracket
6. To remove parking brake cable housing from the body bracket, slide a 14 mm box end wrench
over retainer end compressing the three fingers.
Alternate method is to use an aircraft type hose clamp.
7. Remove the brake shoes from the brake support plate. 8. Disconnect parking brake cable from
parking brake actuator lever.
Removing Park Brake Cable From Brake Support Plate
9. Remove the parking brake cable housing retainer from the brake support plate using a 14 mm
wrench to compress the retaining fingers.
INSTALLATION
1. Install the rear parking brake cable in the brake support plate. Insert cable housing retainer into
brake support plate making certain that cable
housing retainer fingers lock the housing and retainer firmly into place.
2. Attach the parking brake cable onto the park brake actuator lever. 3. Install the brake shoes on
the rear brake support plate. 4. Insert cable housing retainer into body outrigger bracket making
certain that cable housing retainer fingers lock the housing firmly into place. 5. Connect rear
parking brake cable to the equalizer bracket. 6. Install brake drum, and wheel and tire assembly. 7.
Remove the locking pliers from the front park brake cable. This will automatically adjust the park
brake cables. 8. Apply and release park brake pedal 1 time. This will seat the park brake cables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 4380
Parking Brake Cable: Service and Repair Right Rear Cable Replacement
REMOVAL
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear tire and wheel assembly. 3.
Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake
cable.
Locking Out Automatic Adjuster
4. Create slack in the rear parking brake cables by locking out the automatic adjuster as described
here. Grasp an exposed section of front parking
brake cable near the equalizer and pull down on it. At this time install a pair of locking pliers on the
cable just rearward of the second body outrigger bracket.
Intermediate Cable Attachment To Right Rear Cable
5. Disconnect the right rear parking brake cable from the connector on the intermediate cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 4381
Right Park Brake Cable Removal From Body Bracket
6. To remove the right parking brake cable housing from the body bracket, slide a 14 mm box end
wrench over the end of cable retainer to compress
the retaining fingers. The alternate method using an aircraft type hose clamp will not work on the
right side of the vehicle.
7. Remove the brake shoes from the brake support plate. 8. Disconnect parking brake cable from
parking brake actuator lever.
Removing Park Brake Cable From Brake Support Plate
9. Remove the parking brake cable housing retainer from the brake support plate using a 14mm
wrench to compress the retaining fingers. Remove
the cable.
INSTALLATION
1. Install the rear parking brake cable in the brake support plate. Insert cable housing retainer into
brake support plate making certain that cable
housing retainer fingers lock the housing and retainer firmly into place.
2. Attach the parking brake cable onto the parking brake actuator lever. 3. Install the brake shoes
on the rear brake support plate. 4. Insert cable housing retainer into body outrigger bracket making
certain that cable housing retainer fingers lock the housing firmly into place. 5. Connect the right
rear parking brake cable to the connector on the intermediate parking brake cable. 6. Install the
brake drum, then the wheel and tire assembly. 7. Remove the locking pliers from the front park
brake cable. This will automatically adjust the park brake cables. 8. Lower the vehicle. 9. Apply and
release park brake pedal 1 time. This will seat the park brake cables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Information > Specifications
Parking Brake Pedal: Specifications
Mounting Bolts .....................................................................................................................................
............................................... 28 Nm (250 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Information > Specifications > Page 4385
Parking Brake Pedal: Service and Repair
REMOVAL
1. Manually release the automatic self-adjusting mechanism tension of the parking brake lever
(pedal) assembly. 2. Disconnect negative (ground) cable from the battery and isolate cable from
battery terminal. 3. Remove sill scuff plate from left door sill. 4. Remove the left side kick panel. 5.
Remove the steering column cover from the lower instrument panel. 6. Remove the reinforcement
from the lower instrument panel.
Parking Brake Cable Attachment To Equalizer
7. Remove the front parking brake cable from the parking brake cable equalizer. 8. Remove
tension from front park brake cable. Tension is removed by releasing the locking pliers from the
front park brake cable. 9. Remove the 3 bolts mounting the wiring junction block to the instrument
panel.
NOTE: When removing the lower mounting bolt, push the park brake pedal down 5 clicks to access
the lower mounting bolt.
10. Remove the lower bolt mounting the park brake pedal to the body. 11. Remove the forward bolt
mounting the park brake pedal to the body. 12. Remove the upper bolt mounting the park brake
pedal to the body.
Park Brake Pedal Mounting
13. Disconnect the electrical connector for the brake light switch. 14. Pull downward on front park
brake cable while rotating park brake pedal mechanism out from behind junction block. 15.
Remove park brake pedal release cable from park brake mechanism. 16. Remove the ground
switch for the red brake warning lamp from the park brake pedal mechanism. 17. Remove front
park brake cable button from park brake pedal mechanism. Tap end housing of front park brake
cable out of park brake pedal
mechanism.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Information > Specifications > Page 4386
INSTALLATION
1. Install the ground switch for the red BRAKE warning lamp on the park brake pedal mechanism 2.
Install park brake cable end housing into park brake pedal mechanism. 3. Install cable retainer onto
the park brake cable strand and then install retainer into pedal bracket. 4. Install cable strand
button into the clevis on the park brake pedal mechanism. 5. Install wiring harness connector on
red BRAKE warning lamp ground switch. 6. Install the park brake release cable on the release
mechanism of the park brake pedal. 7. Position the park brake pedal mechanism into its installed
position on the body of the vehicle. 8. Loosely install the top bolt mounting the park brake pedal
mechanism to the body. 9. Loosely install the forward bolt mounting the park brake pedal
mechanism to the body.
10. Loosely install the lower bolt mounting the park brake pedal mechanism to the body. 11.
Tighten pedal mechanism attaching bolts to 28 Nm (250 inch lbs.). 12. Verify that the park brake
pedal is in the fully released (full up) position. 13. Raise vehicle. 14. Install the front park brake
cable on the park brake cable equalizer.
NOTE: If the original lever assembly is being used, the lever mechanism auto adjuster spring
tension will need to be reset. After the cable to equalizer bracket connection has been made,
release the pliers, thus allowing the automatic adjuster to take set.
15. Lower vehicle. 16. Remove the lock-out pin (if a new lever has been installed) from the
automatic cable adjuster on the park brake pedal mechanism. 17. Install the electrical junction
block on the instrument panel. 18. Install the reinforcement on the lower instrument panel. 19.
Install the steering column cover on the lower instrument panel. 20. Install the left side kick panel.
21. Install the sill scuff plate on the lower sill of the left door. 22. Install the negative (ground) cable
on the battery. 23. Cycle the park brake pedal one time. This will seat the park brake cables and
will allow the automatic self adjuster to properly tension the park
brake cables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Adjustments
Parking Brake Shoe: Adjustments
PARKING BRAKE SHOES (WITH REAR DISC BRAKES)
CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the fully released position, the park brake shoes can
not be accurately adjusted.
1. Raise vehicle. 2. Remove tire and wheel.
Disc Brake Caliper
3. Remove disc brake caliper from caliper adapter. 4. Remove rotor from hub/bearing.
NOTE: When measuring the brake drum diameter, the diameter should be measured in the center
of the area in which the park brake shoes contact the surface of the brake drum.
Measuring Park Brake Drum Diameter
5. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, accurately measure the inside
diameter of the park brake drum portion of the
rotor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Adjustments > Page 4390
Reading Park Brake Drum Diameter
6. Using a ruler that reads in 64th of an inch, accurately read the measurement of the inside
diameter of the park brake drum from the special tool.
Setting Gauge To Park Brake Shoe Measurement
7. Reduce the inside diameter measurement of the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake
Shoe, Special Tool C-3919 or the equivalent used, so that the outside measurement jaws are set to
the reduced measurement.
8. Place Gauge, Brake Shoe, Special Tool C-3919, or equivalent over the park brake shoes. The
special tool must be located diagonally across at the
top of one shoe and bottom of opposite shoe (widest point) of the park brake shoes.
9. Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake
shoes just touches the jaws on the special tool.
10. Repeat step 8 above and measure shoes in both directions. 11. Install brake rotor on hub and
bearing. 12. Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If
park brake shoes are dragging, remove rotor and back off
star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the
previous step until brake shoes are not dragging on brake drum.
13. Install disc brake caliper on caliper adapter. 14. Install wheel and tire. 15. Tighten the wheel
mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then
repeat the tightening sequence
to the full specified torque of 129 Nm (95 ft. lbs.).
16. Lower vehicle. 17. Apply and release the park brake pedal one time. This will seat and correctly
adjust the park brake cables.
CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
18. Road test the vehicle to ensure proper function of the vehicle's brake system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal
Parking Brake Shoe: Service and Repair Removal
On this vehicle, the park brake shoes are removed from the disc brake adapter removed from the
vehicle.
1. Set the parking brake. The parking brake is set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut. 2. Raise vehicle. Vehicle is to be raised and supported on
jackstands or on a frame contact type hoist. 3. Remove the wheel/tire.
Cotter Pin And Nut Retainer
4. Remove the cotter pin and nut retainer from the stub shaft of the outer C/V joint.
Spring Washer
5. Remove the spring washer from the stub shaft of the outer C/V joint.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 4393
Hub Nut and Washer
6. Remove the hub nut and washer from the stub shaft of the outer C/V joint. 7. Release the
parking brake.
Locking Out Automatic Adjuster
8. Create slack in the rear park brake cables by locking the out the automatic adjuster as
described. Grasp the exposed section of front park brake
cable and pull downward on it. Then install a pair of locking pliers on the front park brake cable just
rearward of the second body outrigger bracket.
Removing Caliper Guide Pin Bolts
9. Remove the disc brake caliper to adapter guide pin bolts.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 4394
Removing/Installing Caliper
10. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter.
Correctly Supported Caliper
11. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. 12.
Remove the rotor from the hub/bearing.
Park Brake Cable Attachment To Actuator
13. Remove the horseshoe clip from the retainer on the end of the park brake cable. 14. Remove
the end of the park brake cable from the actuator lever on the adapter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 4395
Park Brake Cable Removal From Adapter
15. Remove the end of the park brake cable from the adapter. Park brake cable is removed from
adapter using a 1/2 wrench slipped over the park
brake cable retainer as show in to compress the locking tabs on the park brake cable retainer.
Speed Sensor Attaching Bolt
16. Remove the attaching bolt from the wheel speed sensor. Then remove wheel speed sensor
from hub/bearing and adapter.
Hub/Bearing Mounting Bolts
17. Remove the hub/bearing to axle mounting bolts.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 4396
Hub/Bearing Removal And Installation
18. Remove the hub/bearing from the axle and the stub shaft of the outer C/V joint. 19. Remove the
adapter from the rear axle.
Adapter Mounted In Vise
20. Mount the adapter in a vise using the anchor boss for the park brake cable.
Lower Return Spring
21. Remove the lower return spring from the leading and trailing park brake shoes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 4397
Leading Brake Shoe Hold Down Pin And Spring
22. Remove the hold down spring and pin from the leading park brake shoe.
Brake Shoe Adjuster
23. Remove the adjuster from the leading and trailing park brake shoe.
Primary Brake Shoe Remove/Install
24. Remove the leading park brake shoe from the adapter. Leading brake shoe is removed by
rotating the bottom of the brake shoe inward until the top
of the brake shoe can be removed from the brake shoe anchor. Then remove the upper return
springs from the leading brake shoe.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 4398
Upper Return Springs
25. Remove the upper return springs from the trailing park brake shoe.
Trailing Brake Shoe Hold Down Pin And Spring
26. Remove the hold down spring and pin from the trailing park brake shoe. 27. Remove the trailing
park brake shoe from the adapter. 28. Remove the park brake shoe actuator from the adapter and
inspect for signs of abnormal wear and binding at the pivot point.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 4399
Parking Brake Shoe: Service and Repair Installation
1. Install the trailing brake shoe on the adapter.
NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter.
2. Install the hold down spring and pin on the trailing park brake shoe. 3. Install the upper return
springs on the trailing park brake shoe. 4. Install the upper return springs on the leading park brake
shoe. Then position the top of the leading park brake shoe at the upper anchor and rotate
the bottom of the shoe outward until correctly installed on the adapter.
5. Install the adjuster between the leading and trailing park brake shoe.
NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter.
6. Install the hold down spring and pin on the leading park brake shoe. 7. Install the lower return
spring on the leading and trailing park brake shoes. When installing the hold down spring it is to be
installed behind the
park brake shoes.
8. Install the 4 mounting bolts for the adapter and hub/bearing into the bolt holes in the axle.
Adapter Installed On Mounting Bolts
9. Position the adapter on the 4 mounting bolts installed in the rear axle.
10. Install the hub/bearing on the stub shaft of outer C/V joint and into the end of the axle. 11. In a
progressive cries-cross pattern, tighten the 4 hub/bearing mounting bolts until the hub/bearing is
squarely seated against the axle. Then tighten
the hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.).
12. Install the wheel speed sensor on the hub/ bearing and adapter. Install the wheel speed sensor
attaching bolt. Tighten the wheel speed sensor
attaching bolt to a torque of 12 Nm (105 in. lbs.).
13. Install the park brake cable into its mounting hole in the adapter. Be sure all the locking tabs on
the park brake cable retainer are expanded out to
ensure the cable will not pull out of the adapter.
14. Install the end of the park brake cable on the park brake actuator lever.
NOTE: The horseshoe clip must be installed and installed properly when the park brake cable is
installed in the adapter. The purpose of the horseshoe clip is to prevent park brake cable retainer
from moving in the adapter. If horseshoe clip is not installed the park brake cable retainer will rattle
in the adapter.
15. Install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip is installed
between the retainer for the park brake cable and the
adapter. Horseshoe clip must be installed with the curved end of the clip pointing straight up and
the edge of the curved end facing toward the rear of the vehicle.
16. Remove the locking pliers from the front park brake cable. 17. Adjust the park brake
drum-in-hat brake shoes. 18. Install the rotor on the hub/bearing. 19. Carefully lower caliper and
brake shoes over rotor and onto the adapter using the reverse procedure for removal.
CAUTION: When installing guide pin bolts extreme caution should be taken not to crossthread the
caliper guide pin bolts.
20. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch
lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 4400
21. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and
hub nut on the stub shaft of the outer C/V joint. 22. Set the parking brake. 23. Tighten the hub nut
to a torque of 244 Nm (180 ft. lbs.). 24. Install the spring washer on the stub shaft of the outer C/V
joint. 25. Install the nut retainer and cotter pin on the stub shaft of the outer C/V joint. 26. Install the
wheel and tire assembly. 27. Tighten the wheel mounting stud nuts in proper sequence until all
nuts are torqued to half specification. Then repeat the tightening sequence to the
full specified torque of 129 Nm (95 ft. lbs.).
28. Remove jackstands or lower hoist. 29. Fully apply and release the park brake pedal one time.
This will seat and correctly adjust the park brake cables.
CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a
firm brake pedal to adequately stop vehicle.
30. Road test the vehicle and make several stops to wear off any foreign material on the brakes
and to seat the brake shoe linings.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications
Vacuum Brake Booster: Specifications
DIMENSIONS:
Mounting Stud Size .............................................................................................................................
.............................................................. M8 x 1.25 Boost At 20 Inches Of Manifold Vacuum
........................................................................................................................................... 3800 Nm
(850 lbs.)
TIGHTENING TORQUES:
To Dash Panel Mounting Nuts
........................................................................................................................................................ 28
Nm (250 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 4405
Vacuum Brake Booster: Description and Operation
All vehicles use a 270 mm single diaphragm power brake vacuum booster.
Power Brake Booster Identification
The power brake booster can be identified if required, by the tag attached to the body of the
booster assembly. This tag contains the following information: The production part number of the
power booster assembly, the date it was built, and who was the manufacturer of the power brake
vacuum booster.
NOTE: The power brake booster assembly is not a repairable component and must be replaced as
a complete assembly if it is found to be faulty in any way. The check valve located in the power
brake booster is not repairable but it can be replaced as an assembly separate from the power
brake booster.
The power brake booster reduces the amount of force required by the driver to obtain the
necessary hydraulic pressure to stop vehicle.
Power Brake Booster Assembly
The power brake booster is vacuum operated. The vacuum is supplied from the intake manifold on
the engine through the power brake booster check valve.
As the brake pedal is depressed, the power brake booster's input rod moves forward. This opens
and closes valves in the power booster, allowing atmospheric pressure to enter on one side of a
diaphragm. Engine vacuum is always present on the other side. This difference in pressure forces
the output rod of the power booster out against the primary piston of the master cylinder. As the
pistons in the master cylinder move forward this creates the hydraulic pressure in the brake
system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 4406
The different engine combinations used on this vehicle require that different vacuum hose routings
to the power brake vacuum booster be used.
All vacuum hoses must be routed from the engine to the power brake vacuum booster without
kinks, excessively tight bends, or potential for damage to the vacuum hose.
The power brake vacuum booster assembly mounts on the engine side of the dash panel, and is
connected to the brake pedal by the input push rod. A vacuum line connects the power booster to
the intake manifold. The master cylinder is bolted to the front of the power brake vacuum booster
assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement
Vacuum Brake Booster: Service and Repair Vacuum Booster Replacement
Removal
CAUTION: Reserve vacuum in the booster must be pumped down (removed) before removing
master cylinder from vacuum booster. This is necessary to prevent the vacuum booster from
sucking in any contamination as the master cylinder is removed. This can be done simply by
pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is
achieved.
1. With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes). 2.
Remove both battery cables from battery. 3. Remove the battery thermal guard and the battery
from the battery tray. 4. Remove the air inlet resonator and hoses as an assembly from the throttle
body and air cleaner housing. 5. If vehicle is equipped with speed control, unplug wiring harness
connector from the speed control servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery tray.
6. Remove bolt attaching the speed control servo bracket to the battery tray. Slide the bracket
forward to unhook it from the battery tray and remove.
Battery Tray Mounting Locations
7. Remove the 2 bolts and the nut attaching the battery tray to the body of the vehicle.
Electrical Connector At EGR Transducer
8. Remove the wiring harness connector from the EGR valve transducer.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 4409
Electrical And Vacuum Connections To Throttle Body
9. Remove wiring harness connectors from throttle position sensor and AIS motor on throttle body.
Throttle Body Attachment To Intake Manifold
10. Remove the 2 bolts attaching the throttle body to the intake manifold and the clip attaching the
wiring harness to the throttle cable bracket. Then
remove the throttle body and throttle cable bracket as an assembly from the intake manifold.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 4410
Fluid Level Sensor Electrical Connection
11. Remove wiring harness connector from brake fluid level sensor in master cylinder fluid
reservoir. 12. Clean the area where the master cylinder assembly attaches to the power brake
booster. Use only a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
Master Cylinder Attachment To Vacuum Booster
13. Remove clip, attaching drain hose for wiper module to brake tube at master cylinder. Remove
drain hose from wiper module. Remove the 2 nuts,
attaching the master cylinder to the vacuum booster.
NOTE: It is not necessary to remove the brake tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
14. Remove master cylinder and brake tubes as an assembly from the vacuum booster. When
master cylinder is removed, lay it out of the way on top
of the left motor mount.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 4411
EGR Valve Attachment To Intake Manifold
15. Remove the EGR Valve and the vacuum transducer as an assembly from the intake manifold.
16. Disconnect vacuum hose from check valve located on vacuum booster. Do not remove check
valve from power brake booster.
Vacuum Booster Input Rod Retaining Pin
17. Locate the vacuum booster input rod to brake pedal connection under the instrument panel.
Position a small screwdriver between the center tang
on the power brake booster input rod to brake pedal pin retaining clip.
18. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal
pin. Then pull retaining clip off brake pedal pin.
Discard retaining clip. It is not to be reused. Replace only with a new retaining clip when
assembling.
19. Remove the 4 nuts attaching the power brake vacuum booster to the dash panel. Nuts are
accessible from under dash panel in area of the steering
column and pedal bracket assembly.
20. From outside the vehicle, slide power brake vacuum booster forward until its mounting studs
clear dash panel. Then tilt the booster up and toward
the center of vehicle to remove.
CAUTION: Do not attempt to disassemble the power brake vacuum booster it is to be serviced only
as a complete assembly.
Installation
CAUTION: When installing the power brake vacuum booster in the vehicle be sure the heater
hoses do not become trapped between the booster and the dash panel of the vehicle.
1. Position vacuum booster on dash panel using the reverse procedure of its removal. 2. Install the
4 nuts mounting the vacuum booster to the dash panel. Tighten the 4 mounting nuts to a torque of
29 Nm (250 inch lbs.). 3. Using lubriplate, or an equivalent, coat the surface of the brake pedal pin
where it contacts the vacuum booster input rod.
CAUTION: When installing the brake pedal pin on the power brake vacuum booster input rod, do
not re-use the old retaining clip.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 4412
Retaining Pin Installed On Brake Pedal Pin
4. Install vacuum booster input rod on brake pedal pin and install a NEW retaining clip. 5. Connect
the vacuum hose on the check valve in the power brake vacuum booster. 6. Install EGR Valve and
vacuum transducer on the intake manifold. Install and tighten the 2 EGR valve mounting bolts to a
torque of 22 Nm (200
inch lbs.).
CAUTION: ^
The master cylinder is used to create the seal for holding vacuum in the vacuum booster. The
vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master
cylinder is removed from the vacuum booster.
^ When removing the vacuum seal from the master cylinder do not use a sharp tool.
7. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting
flange.
Vacuum Seal Installed On Master Cylinder
8. Install a NEW vacuum seal on mounting flange of the master cylinder. 9. Position master
cylinder on studs of vacuum booster, aligning push rod on vacuum booster with master cylinder
piston.
10. Install the 2 nuts mounting the master cylinder to the vacuum booster. Tighten both mounting
nuts to a torque of 25 Nm (225 inch lbs.). 11. Install the wiper module drain hose on the wiper
module. Install the tie strap attaching the wiper module drain hose to brake tube at the master
cylinder. Tie strap should be loosely tightened so as not to collapse the wiper module drain hose.
12. Install the wiring harness connector on the brake fluid level sensor in the master cylinder fluid
reservoir. 13. Install the throttle body and throttle cable bracket on the intake manifold. Install the 2
bolts attaching the throttle body to the intake manifold and
tighten to a torque of 25 Nm (225 inch lbs.) Install clip attaching the wiring harness to the throttle
cable bracket.
14. Install the wiring harness connectors on the throttle position sensor and the AIS motor on
throttle body. 15. Install the wiring harness connector on the EGR valve transducer. 16. Install the
battery tray. Install the 2 bolts and the nut attaching the battery tray to the vehicle. Tighten the 2
bolts and the nut to a torque of 14 Nm
(125 inch lbs.).
17. If vehicle is equipped with speed control, install the speed control servo and bracket on the
battery tray. Install and securely tighten bolt attaching
bracket to battery tray.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 4413
18. If vehicle is equipped with speed control, install the wiring harness connector on the speed
control servo. Then connect the vacuum lines onto the
speed control servo and vacuum reservoir on battery tray.
19. Install the air inlet resonator and hoses as an assembly on the throttle body and air cleaner
housing. Securely tighten hose clamp at air cleaner
housing and throttle body.
20. Install the battery and the battery thermal guard. 21. Install the battery cables on the battery.
22. Check the operation of the stop lamp switch and adjust if necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 4414
Vacuum Brake Booster: Service and Repair Master Cylinder to Power Brake Booster Vacuum Seal
1. Remove the master cylinder from the power brake vacuum booster. 2. Using a soft tool such as
a trim stick, remove the vacuum seal from the master cylinder mounting flange. 3. Using Mopar
Brake Parts Cleaner or an equivalent, thoroughly clean end of master cylinder housing and master
cylinder push rod.
Vacuum Seal Installed On Master Cylinder
4. Install new master cylinder to power brake booster vacuum seal on master cylinder. When
installing new vacuum seal, be sure it is squarely seated
against master cylinder mounting flange and in groove of push rod.
5. Bleed the master cylinder assembly prior to installing it on the power brake vacuum booster. 6.
Install master cylinder assembly on the power brake vacuum booster. 7. Road test vehicle to
ensure proper operation of the vehicle's power brake system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main
Relay > Component Information > Description and Operation
ABS Main Relay: Description and Operation
ABS FUSES
The ABS system fuse and the ABS pump/motor fuse are located in the Power Distribution Center
(PDC). Refer to the sticker on the inside of the PDC cover for the location of these fuses. The PDC
is located on the driver's side of the engine compartment. The fuse for the amber ABS warning
lamp is located in the fuse junction block under the instrument panel.
If the vehicle is equipped with traction control, the fuse for the traction control switch is located in
the fuse junction block under the instrument panel.
ABS RELAYS
Two relays are used to control the antilock brake system. The two relays are the pump/motor relay
and the system relay. The pump/motor relay and the system relay are located in the CAB. If either
the pump/motor relay or the system relay is diagnosed as not functioning properly, the CAB must
be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications
Electronic Brake Control Module: Specifications
To HCU Mounting Bolts .......................................................................................................................
.................................................. 2 Nm (17 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 4422
Controller Antilock Brake (CAB)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 4423
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 4424
Electronic Brake Control Module: Description and Operation
The Controller Antilock Brake (CAB) is a microprocessor-based device which monitors the ABS
system during normal braking and controls it when the vehicle is in an ABS stop. The CAB is
mounted to the bottom of the HCU. The CAB uses a 25-way electrical connector on the vehicle
wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON
position. The CAB is on the CCD bus.
The primary functions of the (CAB) are to: 1. monitor the antilock brake system for proper
operation. 2. detect wheel locking or wheel slipping tendencies by monitoring the speed of all four
wheels of the vehicle. 3. control fluid modulation to the wheel brakes while the system is in an ABS
mode or the traction control system is activated. 4. store diagnostic information. 5. provide
communication to the DRB scan tool while in diagnostic mode.
The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a
fault, it will turn on the amber ABS warning lamp and disable the antilock braking system. The
normal base braking system will remain operational.
The CAB continuously monitors the speed of each wheel through the signals generated by the
wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking
tendency is detected, the CAB commands the CAB command coils to actuate. The CAB command
coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all
of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until
a locking tendency is no longer present.
The CAB contains a self-diagnostic program that monitors the antilock brake system for system
faults. When a fault is detected, the amber ABS warning lamp is turned on and the fault Diagnostic
Trouble Code (DTC) is then stored in a diagnostic program memory. These DTCs will remain in the
CAB memory even after the ignition has been turned off. The DTCs can be read and cleared from
the CAB memory by a technician using the DRB scan tool. If not cleared with a DRB scan tool, the
fault occurrence and DTC will be automatically cleared from the CAB memory after the identical
fault has not been seen during the next 255 key cycles of vehicle operation or 3,600 miles,
whichever comes first.
CONTROLLER ANTILOCK BRAKE INPUTS
- wheel speed sensors (four)
- stop lamp switch
- ignition switch
- system relay voltage
- ground.
- traction control lamp (if equipped)
- diagnostic communication (CCD)
CONTROLLER ANTILOCK BRAKE OUTPUTS
- body controller communication
- amber ABS warning lamp actuation
- traction control lamp (if equipped)
- diagnostic communication (CCD)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Service and Repair
Brake Fluid Level Sensor/Switch: Service and Repair
The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for
replacement of the brake fluid level switch.
REMOVAL
Fluid Level Sensor Electrical Connection
1. Remove wiring harness connector from brake fluid reservoir level switch.
Master Cylinder Brake Fluid Level Switch
2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With
retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master
cylinder brake fluid reservoir.
INSTALLATION
1. Insert the brake fluid level switch into brake fluid reservoir. Be sure switch is pushed in until
retaining tabs lock it to the brake fluid reservoir. 2. Connect the vehicle wiring harness connector to
the brake fluid level switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations
Traction Control Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Harness Side
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Harness Side > Page 4434
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Page 4435
Traction Control Switch: Testing and Inspection
Traction Control Switch Connector
1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading
between pins.
Traction Control Switch Continuity
Switch Position = Continuity between Actuated = Pins 1 and 2 Illumination = Pins 1 and 3
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Page 4436
Traction Control Switch: Service and Repair
Battery Negative Cable
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the over steering column bezel. 3.
Remove the two screws attaching traction control switch to the bezel.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Specifications > Electrical Specifications
Wheel Speed Sensor: Electrical Specifications
Allowable Resistance 900 - 1300 ohms
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 4441
Wheel Speed Sensor: Mechanical Specifications
Front Rear
Minimum Clearance 0.014 in 0.016 in
Maximum Clearance 0.047 in 0.047 in
To Axle Or Steering Knuckle Mounting Bolt 105 in.lb 105 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors
Front Wheel Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 4444
Rear Wheel Speed Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Front
Wheel Speed Sensor: Diagrams Front
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Front > Page 4447
Wheel Speed Sensor: Diagrams Rear
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Page 4448
Wheel Speed Sensor: Description and Operation
Front Wheel Speed Sensor
Rear Wheel Speed Sensor (FWD)
One Wheel Speed Sensor (WSS) and one tone wheel are located at each front and rear wheel.
Each front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel
is part of the outboard constant velocity joint. The rear wheel speed sensor on rear disc brake
applications is mounted to the rear disc brake adapter. The rear tone wheel is an integral part of
the rear wheel hub and bearing.
The wheel speed sensor sends a small AC signal to the CAB. This signal is generated by magnetic
induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic wheel
speed sensor. The CAB converts the AC signal into a digital signal. If a wheel locking tendency is
detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s)
from locking.
Correct ABS operation is dependent on accurate wheel speed signals. The vehicle's tires and
wheels all must be the same size and type to generate accurate signals. Variations in tire and
wheel size can produce inaccurate wheel speed signals.
Improper speed sensor-to-tone wheel clearance can cause erratic speed sensor signals. The
speed sensor air gap is not adjustable, but should be checked when applicable. Wheel speed
sensor-to-tone wheel clearance specifications can be found in Specifications.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Page 4449
Wheel Speed Sensor: Testing and Inspection
Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following
possible causes. missing, chipped, or broken teeth
- contact with the wheel speed sensor
- wheel speed sensor to tone wheel alignment
- wheel speed sensor to tone wheel clearance
- excessive tone wheel runout
- tone wheel loose on its mounting surface
If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt
should be made to replace just the tone wheel.
If a rear tone wheel is found to need replacement on front-wheel-drive models, the tone wheel is
serviceable separately. If a rear tone wheel is found to need replacement on all-wheel-drive
models, the drive shaft must be replaced. No attempt should be made to replace just the tone
wheel.
If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before
replacing the wheel speed sensor or tone wheel.
Check the gap between the speed sensor head and the tone wheel to ensure it is within
specifications.
Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. If tone wheel
runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and
bearing. Replace as necessary.
Tone wheels are pressed onto their mounting surfaces and should not rotate independently from
the mounting surface. Replacement of the front driveshaft or rear hub and bearing is necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement
Front
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
Front Speed Sensor Cable Channel Bracket
3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame
rail.
CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not
to damage pins on connector.
Speed Sensor Cable To Vehicle Wiring Harness
4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect
speed sensor cable from vehicle wiring harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4452
Front Wheel Speed Sensor Attaching Bolt
5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor
head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON
SENSOR HEAD. Use a
hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free.
Front Wheel Speed Sensor Cable Routing
7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front
wheel speed sensor assembly from the vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as
shown may result in contact with moving parts and/or over extension of cables, resulting in an open
circuit.
1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure
speed sensor cable connector is fully seated and
locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut
tower.
CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the
channel bracket.
2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching
the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4.
Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to
steering knuckle on the rearward side of the
stabilizer bar link.
5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor
attaching bolt to a torque of 12 Nm (105 inch lbs.) 6. Check the air gap between the face of the
wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (.047 inches).
7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of
the base and ABS brake systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4453
Rear
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
CAUTION: When unplugging speed sensor cable from vehicle wiring harness, be careful not to
damage pins on the electrical connectors. Also inspect connectors for any signs of previous
damage.
Rear Speed Sensor Cable Connection To Vehicle Wiring Harness
3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from
vehicle wiring harness.
CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during removal of the speed sensor cable.
Speed Sensor Cable Attachment To Brake Flex Hose
4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4454
Right Rear Speed Sensor Cable Routing
5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the
axle flange, the brake tube clip and the routing clip
from the track bar bracket on the axle.
Rear Speed Sensor Routing Brackets And Clips
6. Remove the 2 rear wheel speed sensor cable/brake tube routing clips. Then unclip the speed
sensor cable from the routing clips on rear brake tube.
CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor
head in an attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the
sensor from side to side until free.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4455
Rear Wheel Speed Sensor Attaching Bolts
7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not
come loose, do not use pliers. Tap with screw driver
and hammer.
8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed
sensor assembly from vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as
shown may result in contact with moving parts and/or over extension of cables, resulting in an open
circuit.
1. Install wheel speed sensor head. Note the plastic anti rotation pin must be fully seated prior to
installing the attaching bolt.
CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must
be fully seated into the bearing flange.
Rear Wheel Speed Sensor Attaching Bolts
2. Install the wheel speed sensor head to bearing flange attaching bolt. Tighten the attaching bolt to
a torque 12 Nm (105 inch lbs.) 3. Check the air gap between the face of the wheel speed sensor
and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inches).
4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle.
The rear wheel speed sensor cable should be routed
under the rear brake tube.
CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during installation of the wheel speed
sensor cable.
5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear
speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4456
CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed
sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the
vehicle wiring harness, do not force the connectors together. If the connectors are forced together,
damage to the connectors will occur.
7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable
connector is fully seated and locked into vehicle wiring
harness connector.
8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into
the body hole. 9. Install the tire and wheel assembly on vehicle.
10. Road test vehicle to ensure proper operation of the base and ABS braking systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4457
Wheel Speed Sensor: Service and Repair Tone Wheel Replacement
This procedure is for the removal of the ABS rear tone wheel from the rear hub and bearing on
front wheel drive vehicles. Vehicles equipped with AWD have a tone wheel mounted on the
driveshaft outer constant velocity joint and it is serviced with the driveshaft.
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and
tire assembly. 3. Remove rear brake drum from the hub/bearing assembly.
Rear Wheel Speed Sensor
4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage
to the speed sensor during removal and
installation of the hub/bearing assembly.
Rear Hub/Bearing Mounting Bolts
5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4458
Removing Rear Hub/Bearing From Axle
6. Remove the hub/bearing assembly from the rear axle and brake support plate.
Tone Wheel Removal From Hub/Bearing Assembly
7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage
by the vise jaws. Mount the hub/bearing assembly
in a vise. Using Puller, Special Tool C-4693 installed as shown remove the tone wheel from the
hub/bearing assembly.
INSTALL
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 4459
Installing Tone Wheel On Hub/Bearing Assembly
1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3.
Position Driver, Special Tool 6908-1 with undercut
side facing up on top of the tone wheel.
Correctly Installed Tone Wheel
2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3.
Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the
rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the
rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts
into hub/ bearing assembly. Tighten the 4 bolts in a
criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto
flange of rear axle.
6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.) 7. Install the rear
wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and
tighten to a torque of 12 Nm (105
inch lbs.).
8. Check the air gap between the face of the wheel speed sensor and the top surface of the tone
wheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inches).
9. Install the brake drum onto the rear hub/bearing assembly.
10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust
the rear brakes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature
Sensor > Component Information > Description and Operation
Battery Temperature Sensor: Description and Operation
OPERATION
The temperature sensor, in the PCM, is used to determine the battery temperature. This
temperature data, along with data from monitored line voltage, is used by the PCM to vary the
battery charging rate. System voltage will be higher at colder temperatures and is gradually
reduced at warmer temperatures.
The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II
monitors are either enabled or disabled depending upon the battery temperature sensor input
(example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch
Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch
Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 4474
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page
4480
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4481
Ignition Switch Lock Cylinder: Description and Operation
DESCRIPTION
The lock cylinder is inserted in the end of the housing opposite the ignition switch.
OPERATION
Ignition Lock Cylinder Detents
The ignition key rotates the cylinder to 5 different detents: Accessory
- Off (lock)
- Unlock
- On/Run
- Start
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4482
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4483
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations
Transmission Range Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations > Page 4487
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 4492
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 4493
Starter Relay: Diagrams
Power Distribution Center
Engine Starter Motor Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 4494
Starter Relay: Description and Operation
STARTER RELAY-PCM OUTPUT
Double Start Override is a feature that prevents the starter from operating if the engine is already
running. This feature is accomplished with software only. There was no hardware added because
of this feature. To incorporate the unique feature of Double Start Override, it was necessary to use
the PCM (software) to control the starter circuit. To use the PCM it was necessary to separate the
starter relay coil ground from the park neutral switch. The starter relay ground is now controlled
through Pin 60 of the PCM. This allows the PCM to interrupt the ground circuit if other inputs tell it
that the engine is turning. If the starter system is operating properly, it can be assumed that the
override protection is also working.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 4495
Starter Relay: Testing and Inspection
WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK
POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED.
Starter Relay
Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine
compartment. Refer to the PDC label for relay identification and location. Remove the starter relay
from the PDC as described to perform the following tests: 1. A relay in the de-energized position
should have continuity between terminals 87A and 30, and no continuity between terminals 87 and
30. If OK,
go to Step 2. If not OK, replace the faulty relay.
2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +-5 Ohms. If OK, go to
Step 3. If not OK, replace the faulty relay 3. Connect a battery B+ lead to terminals 86 and a
ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity
between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to
Relay Circuit Test procedure. If not OK, replace the faulty relay.
Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage
and should be hot at all times. If OK, go to Step 2. If not OK, repair
the open circuit to the PDC fuse as required.
2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized
position, but is not used for this application. Go to Step
3.
3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the
energized position. This terminal supplies battery
voltage to the starter solenoid field coils. There should be continuity between the cavity for relay
terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the
open circuit to the starter solenoid as required.
4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position.
On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test.
Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start
position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5.
If not OK with an automatic transmission, check for an open or short circuit to the ignition switch
and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test
procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch
pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position
Switch Test procedure.
5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with an
automatic transmission, it is grounded through the
park/neutral position switch only when the gearshift selector lever is in the Park or Neutral
positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity
to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an
open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK,
see the Park/Neutral Position Switch Test procedure. If not OK with a manual transmission, repair
the circuit to ground as required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information >
Description and Operation
Battery Temperature Sensor: Description and Operation
OPERATION
The temperature sensor, in the PCM, is used to determine the battery temperature. This
temperature data, along with data from monitored line voltage, is used by the PCM to vary the
battery charging rate. System voltage will be higher at colder temperatures and is gradually
reduced at warmer temperatures.
The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II
monitors are either enabled or disabled depending upon the battery temperature sensor input
(example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20° F.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications
Alternator: Electrical Specifications
Voltage
Powertrain Control Module (PCM) regulates charging system voltage by controlling the generator
field source (+) circuit.
The voltage range is 12.9 to 15.0 volts
Rated Amps
Nippondenso 90 A HS PN 4727220 ....................................................................................................
..................................................................... 86 amps
Nippondenso 120 A HS PN 4727325AA .............................................................................................
................................................................... 102 amps
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications > Page 4505
Alternator: Mechanical Specifications
Adjusting Strap Bolt 200 in.lb
Adjusting Strap Mounting Bolt 30 ft.lb
Bracket Bolt 30 ft.lb
Pivot Nut 30 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 4506
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 4507
Alternator: Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 4508
Alternator: Application and ID
Type = Nippondenso 90 A HS Part Number = 4727220
Type = Nippondenso 120 A HS Part Number = 4727325AA
Part Number is located on the side of the generator
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 4509
Alternator: Description and Operation
DESCRIPTION
The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the
generator fails for any reason, the entire assembly must be replaced.
OPERATION
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a
current into the windings of the stator coil. Once the generator begins producing sufficient current, it
also provides the current needed to energize the rotor.
The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical
system through the generator, battery, and ground terminals.
Noise emitting from the generator may be caused by: Worn, loose or defective bearings
- Loose or defective drive pulley
- Incorrect, worn, damaged or misadjusted drive belt
- Loose mounting bolts
- Misaligned drive pulley
- Defective stator or diode
- Damaged internal fins
GENERATOR FIELD-PCM OUTPUT
The PCM regulates the charging system voltage within a range of 12.9 to 15.0 volts.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 4510
Alternator: Service and Repair
REMOVAL
1. Release hood latch and open hood.
Removal/Installation Of Battery Cables
2. Disconnect battery negative cable. 3. Remove windshield wiper housing, refer to Windshield
Wipers and Washers for proper procedures. 4. Remove accessory drive belt.
Generator Mounting Bracket
5. Remove bolt holding top of generator mount bracket to engine air intake plenum. 6. Remove
bolts holding outside of generator mount bracket to generator mount plate. 7. Remove bolt holding
top of generator to mount bracket. 8. Remove generator mount bracket from vehicle. 9. Rotate
generator toward rear dash panel.
Generator
10. Disconnect the push-in field wire connector from back of generator. 11. Remove nut holding B+
wire terminal to back of generator. 12. Separate B+ terminal from generator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 4511
Generator Pivot Bolt
13. Remove bolt holding bottom of generator to lower pivot bracket.
Generator
14. Remove generator from vehicle.
INSTALLATION
1. Place generator in position on vehicle. 2. Install bolt to hold bottom of generator to lower pivot
bracket. 3. Place B+ terminal in position on generator. 4. Install nut to hold B+ wire terminal to back
of generator. 5. Connect the push-in field wire connector into back of generator. 6. Rotate
generator forward away from dash panel. 7. Place generator mount bracket in position on vehicle.
8. Install bolt to hold top of generator to mount bracket. 9. Install bolts to hold outside of generator
mount bracket to generator mount plate.
10. Install bolt to hold top of generator mount bracket to engine air intake plenum. 11. Install
accessory drive belt. 12. Install windshield wiper housing, refer to Windshield Wipers and Washers
for proper procedures. 13. Connect battery negative cable. 14. Verify generator charge rate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Description and Operation
Voltage Regulator: Description and Operation
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage
regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced
separately. If replacement is necessary, the PCM must be replaced.
OPERATION
The amount of DC current produced by the generator is controlled by EVR circuitry contained
within the PCM. This circuitry is connected in series with the generators second rotor field terminal
and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field.
The EVR circuitry monitors system line voltage and battery temperature (refer to Battery
Temperature Sensor for more information). It then compensates and regulates generator current
output accordingly Also refer to Charging System Operation for additional information.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair
Ignition Lock: Service and Repair
This article has been updated by technical service bulletin number 19-06-99 Dated Sep. 17, 1999.
Note: This bulletin applies to vehicles equipped with an automatic transaxle.
Ignition Switch Housing Service
The ignition switch housing, p/n 04690523, is now available as a separate service part. This part
eliminates the need to replace the complete steering column assembly if the service issue only
relates to the ignition switch housing.
The service procedure to replace the ignition switch housing is below.
REMOVAL
1. Disconnect negative (ground) cable from the battery and isolate cable from battery terminal.
2. Remove the screws attaching the lower steering column cover to the instrument panel, then
remove the cover from the lower instrument panel.
3. Remove the parking brake release cable from the parking brake release lever, then move the
lower steering column cover out of the way.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 4519
4. Remove the 10 bolts attaching the lower steering column cover liner to the instrument panel,
then remove the lower steering column cover liner.
5. Remove the 3 screws attaching the upper and lower shrouds to the steering column, then
separate and remove both shrouds. 6. Remove the trim bezel on the instrument panel above the
steering column. The trim bezel is mounted to the instrument panel using 2 screws (one
on each side of the column) and retaining clips.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 4520
7. Remove the 2 screws securing the steering column fixed shroud to the steering column, then
remove the shroud.
8. Remove the two screws holding the metal cover in place below the shifter/ignition interlock
linkage, then remove the cover.
9. Disconnect the shifter/ignition interlock link from the lever on the lock cylinder housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 4521
10. Remove the key cylinder. To do this:
- Turn the key placing the key cylinder in the ON position.
- Depress and hold the retaining tab on the bottom of the lock cylinder housing.
- Pull the key cylinder straight out of the lock cylinder housing.
11. Remove the vehicle wiring harness connector from the key cylinder halo lamp. 12. Remove the
key cylinder halo lamp from the lock cylinder housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 4522
13. Remove the ignition switch mounting screw.
14. Depress the two retaining tabs, then remove the ignition switch from the lock cylinder housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 4523
15. Disconnect both tilt mechanism springs from their mounting posts on the tilt housing, then move
them to the side out of the way. 16. While supporting the lock cylinder housing, remove both
mounting screws securing the lock cylinder housing to the column. 17. Remove the lock cylinder
housing from the bottom of the steering column.
INSTALLATION
1. Install the lock cylinder housing in the bottom of the steering column lining up the mounting
holes. 2. Install the self-tapping lock cylinder housing mounting screws through the top of the
column into the housing. Tighten the two mounting screws to
a torque of 11 Nm (100 inch lbs.).
3. Connect both tilt mechanism springs back onto their mounting posts making sure the spring
hooks engage the grooves in the posts. 4. Ensure that the ignition switch and the actuator shaft in
the lock cylinder housing are in the ON position.
5. Carefully install the ignition switch over the actuator shaft. The switch will snap over the retaining
tabs on the housing. 6. Install the ignition switch mounting screw. 7. Install the key cylinder halo
lamp on the lock cylinder housing. 8. Install the vehicle wiring harness connector onto the key
cylinder halo lamp. 9. Install the key cylinder (with key in it turned to the ON position) by sliding it
straight into the lock cylinder housing aligning the retaining tab on
the key cylinder with the hole in the lock cylinder housing.
10. Turn the key to the OFF position and remove the key. 11. Connect the shifter/ignition interlock
link to the lever on the lock cylinder housing by aligning the retaining tab on the lever with the ramp
on the
link, then pushing the two together.
12. Install the metal cover in place below the shifter/ignition interlock linkage using the two screws.
CAUTION: After the completion of step 12 in the installation process, you must verify that the shift
lever interlock functions properly. With ignition
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 4524
key removed from lock cylinder and brake pedal depressed, attempt to shift out of park. If the lever
moves out of the park position you must repeat steps 11 and 12 of the installation procedure.
13. Install the steering column fixed shroud on the steering column using its 2 mounting screws. 14.
Install the trim bezel on the instrument panel above the steering column. The trim bezel is mounted
to the instrument panel using 2 screws (one on
each side of the column) and retaining clips.
15. Install the lower steering column shroud on the steering column. Install and securely tighten the
center screw attaching the lower shroud to the tilt
head on the column.
16. Install the upper steering column shroud over the tilt head of the steering column snapping it
into place on the lower shroud. Install and securely
tighten the 2 remaining screws attaching the upper shroud to the lower shroud.
17. Install the steering column cover liner on the instrument panel below the steering column.
Install and securely tighten the 10 bolts attaching the
steering column cover liner to the instrument panel.
18. Install the parking brake pedal release cable on the parking brake release lever in the lower
steering column cover. 19. Install the lower steering column trim cover on the instrument panel
below the steering column.
Install and securely the screws attaching the lower steering column cover to the instrument panel.
20. Connect the negative (ground) cable on the battery terminal.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 >
Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 >
Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 4534
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: >
23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: >
23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 4540
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Page 4541
Ignition Switch Lock Cylinder: Description and Operation
DESCRIPTION
The lock cylinder is inserted in the end of the housing opposite the ignition switch.
OPERATION
Ignition Lock Cylinder Detents
The ignition key rotates the cylinder to 5 different detents: Accessory
- Off (lock)
- Unlock
- On/Run
- Start
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Page 4542
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Page 4543
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
Transmission Range Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 4547
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications
Starter Motor: Electrical Specifications
Power rating = 1.2 K.w.
Voltage = 12 Volts
Free Running Test Voltage = 11 Amperage Draw = 73 amp
Minimum Speed = 3401 rpm
Solenoid Closing Voltage = 7.5 Volts
Cranking Amperage Draw Test = 150 - 200 amps
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications > Page 4552
Starter Motor: Mechanical Specifications
Starter Mounting Bolt 50 ft.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 4553
Starter Motor: Application and ID
Manufacturer = Nippondenso Brushes = 4 Fields = 4 Poles = 4 Drive = Conventional Gear Train
Engine should be up to operating temperature. Extremely heavy oil or tight engine will increase
starter amperage draw.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 4554
Starter Motor: Service and Repair
REMOVAL
1. Release hood latch and open hood.
Battery Negative Cable
2. Disconnect and isolate the battery negative cable. 3. Hoist and support vehicle on safety stands.
Starter - Engine Wire Connectors
4. Remove nut holding B+ terminal to starter solenoid. 5. Disconnect solenoid connector from
starter.
Starter Bolts
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 4555
6. Remove bolts holding starter to transaxle bell-housing.
Starter
7. Remove starter from bell-housing. 8. Separate starter spacer from transaxle bell-housing.
INSTALLATION
1. Place starter spacer in position on transaxle bell-housing, flange toward flywheel. 2. Place starter
in position on bellhousing. 3. Install bolts to hold starter to transaxle bell-housing. 4. Connect
solenoid connector into starter. 5. Install nut to hold B+ terminal to starter solenoid. 6. Lower
vehicle. 7. Connect battery negative cable. 8. Verify starter operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Starter Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
> Page 4559
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
> Page 4560
Starter Relay: Diagrams
Power Distribution Center
Engine Starter Motor Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
> Page 4561
Starter Relay: Description and Operation
STARTER RELAY-PCM OUTPUT
Double Start Override is a feature that prevents the starter from operating if the engine is already
running. This feature is accomplished with software only. There was no hardware added because
of this feature. To incorporate the unique feature of Double Start Override, it was necessary to use
the PCM (software) to control the starter circuit. To use the PCM it was necessary to separate the
starter relay coil ground from the park neutral switch. The starter relay ground is now controlled
through Pin 60 of the PCM. This allows the PCM to interrupt the ground circuit if other inputs tell it
that the engine is turning. If the starter system is operating properly, it can be assumed that the
override protection is also working.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
> Page 4562
Starter Relay: Testing and Inspection
WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK
POSITION/NEUTRAL WITH THE PARKING BRAKE APPLIED.
Starter Relay
Relay Test The starter relay is located in the Power Distribution Center (PDC) in the engine
compartment. Refer to the PDC label for relay identification and location. Remove the starter relay
from the PDC as described to perform the following tests: 1. A relay in the de-energized position
should have continuity between terminals 87A and 30, and no continuity between terminals 87 and
30. If OK,
go to Step 2. If not OK, replace the faulty relay.
2. Resistance between terminals 85 and 86 (electromagnet) should be 75 +-5 Ohms. If OK, go to
Step 3. If not OK, replace the faulty relay 3. Connect a battery B+ lead to terminals 86 and a
ground lead to terminal 85 to energize the relay. The relay should click. Also test for continuity
between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, refer to
Relay Circuit Test procedure. If not OK, replace the faulty relay.
Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage
and should be hot at all times. If OK, go to Step 2. If not OK, repair
the open circuit to the PDC fuse as required.
2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized
position, but is not used for this application. Go to Step
3.
3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the
energized position. This terminal supplies battery
voltage to the starter solenoid field coils. There should be continuity between the cavity for relay
terminal 87 and the starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair the
open circuit to the starter solenoid as required.
4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position.
On vehicles with a manual transmission, the clutch pedal must be fully depressed for this test.
Check for battery voltage at the cavity for relay terminal 86 with the ignition switch in the Start
position, and no voltage when the ignition switch is released to the On position. If OK, go to Step 5.
If not OK with an automatic transmission, check for an open or short circuit to the ignition switch
and repair, if required. If the circuit to the ignition switch is OK, see the Ignition Switch Test
procedure. If not OK with a manual transmission, check the circuit between the relay and the clutch
pedal position switch for an open or a short. If the circuit is OK, see the Clutch Pedal Position
Switch Test procedure.
5. The coil ground terminal (85) is connected to the electromagnet in the relay On vehicles with an
automatic transmission, it is grounded through the
park/neutral position switch only when the gearshift selector lever is in the Park or Neutral
positions. On vehicles with a manual transmission, it is grounded at all times. Check for continuity
to ground at the cavity for relay terminal 85. If not OK with an automatic transmission, check for an
open or short circuit to the park/neutral position switch and repair, if required. If the circuit is OK,
see the Park/Neutral Position Switch Test procedure. If not OK with a manual transmission, repair
the circuit to ground as required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information >
Testing and Inspection
Starter Solenoid: Testing and Inspection
WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION WITH
THE PARKING BRAKE APPLIED.
1. Verify battery condition. Battery must be in good condition with a full charge before performing
any starter tests. Refer to Battery Tests. 2. Perform Starter Solenoid test BEFORE performing the
starter relay test. 3. Raise the vehicle. 4. Perform a visual inspection of the starter/starter solenoid
for corrosion, loose connections or faulty wiring. 5. Lower the vehicle. 6. Locate and remove the
starter relay from the Power Distribution Center (PDC). Refer to the PDC label for relay
identification and location. 7. Connect a remote starter switch or a jumper wire between the remote
battery positive post and terminal 87 of the starter relay connector.
a. If engine cranks, starter/starter solenoid is good. Go to the Starter Relay Test. b. If engine does
not or solenoid chatters, check wiring and connectors from starter relay to starter solenoid for loose
or corroded connections.
Particularly at starter terminals.
c. Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted
solenoid, and replace starter.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Locations
Auxiliary Power Outlet: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Locations > Page 4570
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4573
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4574
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4575
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4576
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4577
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4578
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4579
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4580
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4581
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4582
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4583
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4584
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4586
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4587
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
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Auxiliary Power Outlet: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 4591
Auxiliary Power Outlet: Connector Views
Power Distribution Center -- Sheet 8w-10-2
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Information > Diagrams > Diagram Information and Instructions > Page 4592
Power Distribution Center -- Sheet 8w-10-4
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information >
Diagrams
Diode: Diagrams
Junction Block
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information >
Diagrams > Page 4596
Diodes
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Locations > Component Locations
Power Distribution Center: Component Locations
Power Distribution Center & Powertrain Control Module (PCM)
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4601
Power Distribution Center: Connector Locations
Connector Pin Identification (Part 1 Of 15)
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4602
Connector Pin Identification (Part 2 Of 15)
Connector Pin Identification (Part 3 Of 15)
Connector Pin Identification (Part 4 Of 15)
Connector Pin Identification (Part 5 Of 15)
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4603
Connector Pin Identification (Part 6 Of 15)
Connector Pin Identification (Part 7 Of 15)
Connector Pin Identification (Part 8 Of 15)
Connector Pin Identification (Part 9 Of 15)
Connector Pin Identification (Part 10 Of 15)
Connector Pin Identification (Part 11 Of 15)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Locations > Component Locations > Page 4604
Connector Pin Identification (Part 12 Of 15)
Connector Pin Identification (Part 13 Of 15)
Connector Pin Identification (Part 14 Of 15)
Connector Pin Identification (Part 15 Of 15)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Locations > Page 4605
Power Distribution Center: Diagrams
Power Distribution Center C1
Power Distribution Center C2
Power Distribution Center C3
Power Distribution Center C4
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Locations > Page 4606
Power Distribution Center C5
Power Distribution Center C6
Power Distribution Center C7
Power Distribution Center C8
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations
Fuse: Locations
For fuse location and identification, refer to Electrical Accessory Panel (Power Distribution Center)
and/or Fuse Block (Junction Block) Locations, Components.
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Page 4610
Fuse: Diagrams
Junction Block
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Page 4611
Junction Block Fuses
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Page 4612
Power Distribution Center
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Page 4613
Power Distribution Center Fuses
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Locations
Fuses
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Fuse Block: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4637
Fuse Block: Connector Views
Junction Block
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Information > Diagrams > Diagram Information and Instructions > Page 4638
Junction Block C1 (A)
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4639
Junction Block C2 (B)
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Information > Diagrams > Diagram Information and Instructions > Page 4640
Junction Block C3 (D)
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4641
Junction Block C4 (C)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4642
Fuse Block: Electrical Diagrams
Except Chrysler
Junction Block -- Sheet 8w-12-8
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4643
Junction Block -- Sheet 8w-12-9
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4644
Junction Block -- Sheet 8w-12-10
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4645
Junction Block -- Sheet 8w-12-11
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4646
Junction Block -- Sheet 8w-12-12
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4647
Junction Block -- Sheet 8w-12-13
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4648
Junction Block -- Sheet 8w-12-14
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Information > Diagrams > Diagram Information and Instructions > Page 4649
Junction Block -- Sheet 8w-12-15
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Information > Diagrams > Diagram Information and Instructions > Page 4650
Junction Block -- Sheet 8w-12-16
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Information > Diagrams > Diagram Information and Instructions > Page 4651
Junction Block -- Sheet 8w-12-17
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Information > Diagrams > Diagram Information and Instructions > Page 4652
Junction Block -- Sheet 8w-12-18
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4653
Junction Block -- Sheet 8w-12-19
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4654
Junction Block -- Sheet 8w-12-20
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4655
Junction Block -- Sheet 8w-12-21
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4656
Junction Block -- Sheet 8w-12-22
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Diagram Information and Instructions > Page 4657
Junction Block -- Sheet 8w-12-23
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Information > Diagrams > Diagram Information and Instructions > Page 4658
Junction Block -- Sheet 8w-12-24
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
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Information > Diagrams > Diagram Information and Instructions > Page 4659
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions
Multiple Junction Connector: Technical Service Bulletins Electrical - Wiring Schematics Revisions
NUMBER: 26-12-99G
GROUP: Miscellaneous
DATE: December, 1999
THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revisions to the wiring schematics
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8W-44-5
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Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4665
8W-44-7
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Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4666
8W-45-7
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Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4667
8W-50-2
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8W-50-5
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Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4669
8W-50-7
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Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4670
8W-80-15
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Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4671
8W-90-3
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Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4672
8W-90-11
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions
Wiring Harness: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out
Revisions
NUMBER: 26-04-99
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
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Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 4677
8N-4
Revision to the Body Control Module connector pin-out
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Information > Technical Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 4678
8W-80-13
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations
Auxiliary Power Outlet: Locations
Battery Negative Cable
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Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations
> Page 4683
Power Distribution Center -- Sheet 8w-10-2
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> Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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> Diagram Information and Instructions > Page 4687
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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> Diagram Information and Instructions > Page 4688
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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> Diagram Information and Instructions > Page 4689
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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> Diagram Information and Instructions > Page 4690
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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> Diagram Information and Instructions > Page 4691
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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> Diagram Information and Instructions > Page 4692
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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> Diagram Information and Instructions > Page 4693
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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> Diagram Information and Instructions > Page 4694
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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> Diagram Information and Instructions > Page 4697
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 4700
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 4701
Auxiliary Power Outlet: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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> Diagram Information and Instructions > Page 4704
Auxiliary Power Outlet: Connector Views
Power Distribution Center -- Sheet 8w-10-2
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> Diagram Information and Instructions > Page 4705
Power Distribution Center -- Sheet 8w-10-4
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Diagrams
Diode: Diagrams
Junction Block
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Diodes
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Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Locations > Component Locations
Power Distribution Center: Component Locations
Power Distribution Center & Powertrain Control Module (PCM)
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Locations > Component Locations > Page 4714
Power Distribution Center: Connector Locations
Connector Pin Identification (Part 1 Of 15)
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Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Locations > Component Locations > Page 4715
Connector Pin Identification (Part 2 Of 15)
Connector Pin Identification (Part 3 Of 15)
Connector Pin Identification (Part 4 Of 15)
Connector Pin Identification (Part 5 Of 15)
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Component Information > Locations > Component Locations > Page 4716
Connector Pin Identification (Part 6 Of 15)
Connector Pin Identification (Part 7 Of 15)
Connector Pin Identification (Part 8 Of 15)
Connector Pin Identification (Part 9 Of 15)
Connector Pin Identification (Part 10 Of 15)
Connector Pin Identification (Part 11 Of 15)
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Component Information > Locations > Component Locations > Page 4717
Connector Pin Identification (Part 12 Of 15)
Connector Pin Identification (Part 13 Of 15)
Connector Pin Identification (Part 14 Of 15)
Connector Pin Identification (Part 15 Of 15)
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Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Locations > Page 4718
Power Distribution Center: Diagrams
Power Distribution Center C1
Power Distribution Center C2
Power Distribution Center C3
Power Distribution Center C4
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Component Information > Locations > Page 4719
Power Distribution Center C5
Power Distribution Center C6
Power Distribution Center C7
Power Distribution Center C8
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations
Fuse: Locations
For fuse location and identification, refer to Electrical Accessory Panel (Power Distribution Center)
and/or Fuse Block (Junction Block) Locations, Components.
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Fuse: Diagrams
Junction Block
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Junction Block Fuses
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Power Distribution Center
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Power Distribution Center Fuses
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Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations
Fuses
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions
Fuse Block: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Fuse Block: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4748
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4749
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4750
Fuse Block: Connector Views
Junction Block
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4751
Junction Block C1 (A)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4752
Junction Block C2 (B)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4753
Junction Block C3 (D)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4754
Junction Block C4 (C)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4755
Fuse Block: Electrical Diagrams
Except Chrysler
Junction Block -- Sheet 8w-12-8
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4756
Junction Block -- Sheet 8w-12-9
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4757
Junction Block -- Sheet 8w-12-10
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4758
Junction Block -- Sheet 8w-12-11
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4759
Junction Block -- Sheet 8w-12-12
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4760
Junction Block -- Sheet 8w-12-13
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4761
Junction Block -- Sheet 8w-12-14
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4762
Junction Block -- Sheet 8w-12-15
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4763
Junction Block -- Sheet 8w-12-16
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4764
Junction Block -- Sheet 8w-12-17
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4765
Junction Block -- Sheet 8w-12-18
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4766
Junction Block -- Sheet 8w-12-19
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4767
Junction Block -- Sheet 8w-12-20
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4768
Junction Block -- Sheet 8w-12-21
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4769
Junction Block -- Sheet 8w-12-22
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4770
Junction Block -- Sheet 8w-12-23
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4771
Junction Block -- Sheet 8w-12-24
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 4772
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions
Multiple Junction Connector: Technical Service Bulletins Electrical - Wiring Schematics Revisions
NUMBER: 26-12-99G
GROUP: Miscellaneous
DATE: December, 1999
THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revisions to the wiring schematics
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4777
8W-44-5
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4778
8W-44-7
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4779
8W-45-7
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4780
8W-50-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4781
8W-50-5
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4782
8W-50-7
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4783
8W-80-15
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4784
8W-90-3
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 4785
8W-90-11
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions
Wiring Harness: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out
Revisions
NUMBER: 26-04-99
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 4790
8N-4
Revision to the Body Control Module connector pin-out
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 4791
8W-80-13
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using
Alternative Fuels or Electric Engine
Alignment: Specifications Vehicles Using Alternative Fuels or Electric Engine
NOTES:
- All specifications are given in degrees.
- All wheel alignments are to be set at curb height.
FRONT:
Camber (All Vehicles Except Those With Tire Sizes P205/75R15, P215/65/R16 or P215/60/R17):
Preferred Setting .................................................................................................................................
..................................................................... +0.15° Acceptable Range ..............................................
........................................................................................................................................ -0.25 to
+0.55°
Camber (Vehicles With Tire Sizes P205/75R15, P215/65/R16 or P215/60/R17): Preferred Setting ..
..............................................................................................................................................................
...................................... +0.05° Acceptable Range .............................................................................
......................................................................................................... -0.25 to +0.55°
Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ...............................................
.........................................................................................................................................................
+0.0° Acceptable Range ......................................................................................................................
................................................................................ 0.50°
Caster [1]: Preferred Setting ................................................................................................................
...................................................................................... +1.40° Acceptable Range .............................
.......................................................................................................................................................
+0.40° to +2.40°
Cross Caster (Maximum Side-to-Side Difference): Preferred Setting .................................................
.........................................................................................................................................................
0.0° Acceptable Range ........................................................................................................................
.............................................................................. 1.00°
Total Toe [2]: Preferred Setting ...........................................................................................................
........................................................................................... +0.10° Acceptable Range ........................
.............................................................................................................................................................
-0.10° to +0.30°
Total Toe (Maximum Side-to-Side Difference): Preferred Setting .......................................................
................................................................................................................................................... 0.0°
Acceptable Range ...............................................................................................................................
....................................................................... 0.06°
Curb Height: Standard
.........................................................................................................................................................
783.5 mm ±10 mm (30.85 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
REAR:
Camber [1]: Preferred Setting ..............................................................................................................
......................................................................................... -0.10° Acceptable Range ..........................
............................................................................................................................................................
-0.35 to +0.15°
Total Toe [1, 2]: Preferred Setting .......................................................................................................
................................................................................................... 0.0° Acceptable Range ....................
..............................................................................................................................................................
... -0.40° to +0.40°
Thrust Angle [1]: Preferred Setting ......................................................................................................
.................................................................................................... 0.0° Acceptable Range ...................
..............................................................................................................................................................
.... -0.30° to +0.30°
Curb Height: Standard
.........................................................................................................................................................
802.5 mm ±10 mm (31.59 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
[1] For reference only. These are non-adjustable angles.
[2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split
between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is
toe-in and negative toe is toe-out.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using
Alternative Fuels or Electric Engine > Page 4797
Alignment: Specifications All Except W/Tire Sizes P205/75/R14, P215/65R/16 or P215/60/R17
NOTES:
- All specifications are given in degrees.
- All wheel alignments are to be set at curb height.
FRONT:
Camber: Preferred Setting ...................................................................................................................
................................................................................... +0.15° Acceptable Range ................................
......................................................................................................................................................
-0.25 to +0.55°
Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ...............................................
.........................................................................................................................................................
+0.0° Acceptable Range ......................................................................................................................
................................................................................ 0.50°
Caster [1]: Preferred Setting ................................................................................................................
...................................................................................... +1.40° Acceptable Range .............................
.......................................................................................................................................................
+0.40° to +2.40°
Cross Caster (Maximum Side-to-Side Difference): Preferred Setting .................................................
.........................................................................................................................................................
0.0° Acceptable Range ........................................................................................................................
.............................................................................. 1.00°
Total Toe [2]: Preferred Setting ...........................................................................................................
........................................................................................... +0.10° Acceptable Range ........................
.............................................................................................................................................................
-0.10° to +0.30°
Total Toe (Maximum Side-to-Side Difference): Preferred Setting .......................................................
................................................................................................................................................... 0.0°
Acceptable Range ...............................................................................................................................
....................................................................... 0.06°
Curb Height: Standard
.........................................................................................................................................................
747.5 mm ±10 mm (29.43 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
REAR:
Camber [1]: Preferred Setting ..............................................................................................................
............................................................................................ 0.0° Acceptable Range ...........................
...........................................................................................................................................................
-0.25 to +0.25°
Total Toe [1, 2]: Preferred Setting .......................................................................................................
................................................................................................... 0.0° Acceptable Range ....................
..............................................................................................................................................................
... -0.40° to +0.40°
Thrust Angle [1]: Preferred Setting ......................................................................................................
.................................................................................................... 0.0° Acceptable Range ...................
..............................................................................................................................................................
.... -0.30° to +0.30°
Curb Height: Standard
.........................................................................................................................................................
766.0 mm ±10 mm (30.15 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
[1] For reference only. These are non-adjustable angles.
[2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split
between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is
toe-in and negative toe is toe-out.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using
Alternative Fuels or Electric Engine > Page 4798
Alignment: Specifications With Tire Sizes P205/75/R14, P215/65R/16 or P215/60/R17
NOTES:
- All specifications are given in degrees.
- All wheel alignments are to be set at curb height.
FRONT:
Camber: Preferred Setting ...................................................................................................................
................................................................................... +0.05° Acceptable Range ................................
......................................................................................................................................................
-0.35 to +0.45°
Cross Camber (Maximum Side-to-Side Difference): Preferred Setting ...............................................
.........................................................................................................................................................
+0.0° Acceptable Range ......................................................................................................................
................................................................................ 0.50°
Caster [1]: Preferred Setting ................................................................................................................
...................................................................................... +1.40° Acceptable Range .............................
.......................................................................................................................................................
+0.40° to +2.40°
Cross Caster (Maximum Side-to-Side Difference): Preferred Setting .................................................
.........................................................................................................................................................
0.0° Acceptable Range ........................................................................................................................
.............................................................................. 1.00°
Total Toe [2]: Preferred Setting ...........................................................................................................
........................................................................................... +0.10° Acceptable Range ........................
.............................................................................................................................................................
-0.10° to +0.30°
Total Toe (Maximum Side-to-Side Difference): Preferred Setting .......................................................
................................................................................................................................................... 0.0°
Acceptable Range ...............................................................................................................................
....................................................................... 0.06°
Curb Height: Standard
.........................................................................................................................................................
753.5 mm ±10 mm (29.66 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
REAR:
Camber [1]: Preferred Setting ..............................................................................................................
............................................................................................ 0.0° Acceptable Range ...........................
...........................................................................................................................................................
-0.25 to +0.25°
Total Toe [1, 2]: Preferred Setting .......................................................................................................
................................................................................................... 0.0° Acceptable Range ....................
..............................................................................................................................................................
... -0.40° to +0.40°
Thrust Angle [1]: Preferred Setting ......................................................................................................
.................................................................................................... 0.0° Acceptable Range ...................
..............................................................................................................................................................
.... -0.30° to +0.30°
Curb Height: Standard
.........................................................................................................................................................
772.0 mm ±10 mm (30.39 inch ±0.39 inch) Maximum Left-to-Right Differential Not to Exceed
............................................................................................................................ 12.5 mm (0.5 inch)
[1] For reference only. These are non-adjustable angles.
[2] Total Toe is the sum of both left and right wheel toe settings. Total Toe must be equally split
between each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is
toe-in and negative toe is toe-out.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4799
Alignment: Description and Operation
Vehicle wheel alignment is the proper adjustment of all interrelated front and rear suspension
angles. These angles are what effects the handling and steering of the vehicle when it is in motion.
The method of checking a vehicle's front and rear wheel alignment will vary depending on the type
and manufacturer of the equipment being used. Instructions furnished by the manufacturer of the
equipment being used should always be followed to ensure accuracy of the alignment, except
when alignment specifications recommended by Chrysler Corporation differ. Typical wheel
alignment angles and measurements are camber, caster, toe, and thrust angle.
Alignment Camber And Toe
- Camber is the number of degrees the top of the tire and wheel are tilted either inward or outward.
Camber is a tire wearing angle. Excessive negative camber will cause tread wear at the inside of
the tire, while excessive positive camber will cause outside tire wear.
- Caster is the number of degrees of forward or rearward tilt of the steering knuckle. Forward tilt
provides a negative caster angle, while rearward tilt provides a positive caster angle. Caster is not
adjustable on this vehicle.
- Cross camber is the difference between left and right camber. The right side camber is to be
subtracted from the left, resulting in the cross camber reading. For example, if the left camber is
+0.3° and the right camber is 0.0°, the cross camber would be +0.3°.
- Toe is measured in degrees or inches and is the difference in width between the centered leading
and trailing edges of the tires on the same axle. Toe-in means that the front width is more narrow
than the rear. Toe-out means that the front width is wider than the rear.
- Thrust angle is defined as the average of the toe settings on each rear wheel. If this measurement
is out of specification, readjust the rear wheel toe so that each wheel has 1/2 of the total toe
measurement. When readjusting, do not exceed the total toe specification.
Wheel alignment on this vehicle is to be checked and all alignment adjustments made with the
vehicle at its curb height specification. Curb height is the riding height of the vehicle measured from
a certain point on the vehicle to the ground while the vehicle is setting on a flat, level surface.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4800
Alignment: Testing and Inspection
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct the wheel alignment, the following inspection and
necessary corrections must be made to the vehicle to ensure proper alignment. 1. Be sure the fuel
tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the curb height of the
vehicle and the alignment
specifications.
2. The passenger and luggage compartments of the vehicle should be free of any load that is not
factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the
recommended air pressure. All tires must be the same size and in good condition
with approximately the same tread wear.
4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension
component fasteners for looseness and torque. 6. Inspect the lower front ball joints and all steering
linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on all the
suspension components for signs of wear or deterioration. If any bushings show signs of wear or
deterioration, they should be replaced prior to aligning the vehicle.
8. Check vehicle curb height to verify it is within specifications. If curb height is out of specifications,
check for broken or sagged springs.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Curb
Height Measurement
Alignment: Service and Repair Curb Height Measurement
The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its
required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level
surface, preferably a vehicle alignment rack. The tires are to be inflated to the recommended
pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with
the fuel tank full of fuel, and no passenger or luggage compartment load. Vehicle height is not
adjustable. If the measurement is not within specifications, inspect the vehicle for bent or weak
suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and
the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil
spring height to a correct new or known good coil spring. The heights should vary if the suspect
spring is weak. 1. Measure from the inboard edge of the wheel opening fender lip directly above
the wheel center (spindle), to the floor or alignment rack surface. 2. When measuring, the
maximum left-to-right differential is not to exceed 12.5 mm (0.5 inch). 3. Compare the
measurements to the specifications.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Curb
Height Measurement > Page 4803
Alignment: Service and Repair Wheel Alignment
1. Position the vehicle on an alignment rack. 2. Perform the PRE-WHEEL ALIGNMENT
INSPECTION. 3. Install all required alignment equipment on the vehicle per the alignment
equipment manufacturer's instructions. On this vehicle, a four-wheel
alignment is recommended.
NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be
jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing
each end of vehicle an equal number of times. The bumper should always be released when
vehicle is at the bottom of the jounce cycle.
4. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current
alignment settings to the vehicle specifications for
camber, caster and toe-in.
5. If front camber and caster are not within specifications, proceed to CAMBER AND CASTER
below. If caster and camber are within
specifications, proceed to TOE which can be found following CAMBER AND CASTER. Rear
camber, caster and toe are not adjustable. If found not to be within specifications, reinspect for
damaged suspension or body components and replace as necessary.
CAMBER AND CASTER
Camber and caster settings on this vehicle are determined at the time the vehicle is designed, by
the location of the vehicle's suspension components. This is referred to as NET BUILD. The result
is no required adjustment of camber and caster after the vehicle is built or when servicing the
suspension components. Thus, when performing a wheel alignment, caster and camber are not
normally considered adjustable angles. Camber and caster should be checked to ensure they meet
vehicle specifications. If front camber is found not to meet alignment specifications, it can be
adjusted using an available camber adjustment bolt package. Before installing a camber
adjustment bolt package on a vehicle found to be outside the specifications, inspect the suspension
components for any signs of damage or bending.
CAUTION: Do not attempt to adjust the vehicles wheel; alignment by heating, bending or by
performing any other modification to the vehicle's front suspension components or body.
If camber readings are not within specifications, use the following procedure to install the front
camber adjustment bolt package and then adjust front camber.
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
The camber adjustment bolt package contains 2 flange bolts, 2 cam bolts, 2 dog bone washers,
and 4 nuts. This package services both sides of the vehicle. Use the package to attach the strut
clevis bracket to the steering knuckle after the strut clevis bracket has been modified. To install and
adjust the camber adjustment bolt package, follow the procedure below. 1. Raise the vehicle until
its tires are not supporting the weight of the vehicle. 2. Remove the front tire and wheel assemblies.
CAUTION: When removing the steering knuckle from the strut clevis bracket, do not put a strain on
the brake flex hose. Also, do not let the weight of the steering knuckle assembly be supported by
the brake flex hose when removed from the strut assembly. If necessary use a wire hanger to
support the steering knuckle assembly or if required remove the brake flex hose from the caliper
assembly.
CAUTION: The knuckle to strut assembly attaching bolt shanks are serrated and must not be
turned during removal. Remove the nuts while holding the bolts stationary.
Clevis Bracket To Steering Knuckle Attaching Bolts
3. Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts and discard.
Separate the steering knuckle from the strut clevis
bracket and position steering knuckle so it is out of the way of the strut.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Curb
Height Measurement > Page 4804
Strut Clevis Bracket Bolt Hole Grinding Area
CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the
hole beyond the indentations on the sides of the strut clevis bracket.
4. Using an appropriate grinder and grinding wheel, slot the bottom hole in both sides of the strut
clevis bracket.
CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assembly. Only the flange bolts, cam bolts, and dog
bone washers from the service package must be used to attach the steering knuckle to the strut
after the mounting hole is slotted.
Package Bolts Correctly Installed (left Shown)
5. Position the knuckle back into the strut clevis bracket. Install a flanged bolt from the service
package into the upper mounting hole. Install a cam
bolt into the bottom mounting hole. Both bolts should point forward once installed.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Curb
Height Measurement > Page 4805
Dog Bone Washer And Nuts Installed On Attaching Bolts
6. Install a dog bone washer on the steering knuckle to strut clevis bracket attaching bolts, then
install the nuts onto the bolts from the service
package. Tighten the bolts just enough to hold the steering knuckle in position when adjusting
camber, while still allowing the steering knuckle to move in clevis bracket.
7. Repeat the procedure to the other side strut clevis bracket. 8. Reinstall both front tire and wheel
assemblies and tighten to specifications. 9. Lower the vehicle. Jounce the front and rear of vehicle
an equal amount of times.
Camber Adjustment Cam Bolt
10. Adjust the front camber to the preferred setting by rotating the lower eccentric cam bolt against
the cam stop areas on the strut clevis bracket.
When camber is set, tighten the upper strut clevis bracket bolt and lower cam bolt. Again jounce
front and rear of vehicle an equal amount of times and verify front camber setting. Torque both
front strut to steering knuckle attaching bolts to 90 Nm (65 ft. lbs.) plus an additional 1/4 turn after
the required torque is met.
11. If toe readings obtained are not within the required specification range, adjust toe to meet the
preferred specification setting. Toe is adjustable
using the following procedure.
TOE
1. Center the steering wheel and lock in place using a steering wheel clamp.
CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe
adjustment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Curb
Height Measurement > Page 4806
Front Wheel Toe Adjustment
2. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate
inner tie rods of steering gear to set front toe to the
preferred toe specification.
3. Tighten tie rod jam nuts to 75 Nm (55 ft. lbs.) torque. 4. Adjust steering gear to tie rod boots at
the inner tie rod. 5. Remove steering wheel clamp. 6. Remove the alignment equipment. 7. Road
test the vehicle to verify the steering wheel is straight and the vehicle does not wander or pull.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications
Front Steering Knuckle: Specifications
Ball Joint Stud Nut/Bolt ........................................................................................................................
............................................... 145 Nm (105 ft. lbs.) Wheel Stop ........................................................
....................................................................................................................................... 95 Nm (70 ft.
lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications > Page 4811
Front Steering Knuckle: Description and Operation
Front Steering Knuckle
The steering knuckle is a single casting with legs machined for attachment of the strut damper,
steering linkage, disc brake caliper, and lower control arm ball joint. The steering knuckle also has
the front hub and bearing mounted to it. The hub and bearing is positioned through the knuckle,
with the drive shaft constant velocity stub shaft splined through the center of the hub.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications > Page 4812
Front Steering Knuckle: Testing and Inspection
The front suspension knuckle is not a repairable component of the front suspension. It must be
replaced. If bent, broken, or damaged in any way, do not attempt to straighten or repair the steering
knuckle. Service replacement of the front hub/bearing assembly can be done with the front steering
knuckle remaining on the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal
Front Steering Knuckle: Service and Repair Removal
REMOVAL
1. Raise vehicle on jack stands or centered on a frame contact type hoist.
Hub And Bearing To Stub Axle Retaining Nut
2. Remove the cotter pin and nut lock from the end of the stub axle. 3. Remove the wheel and tire
assembly from the vehicle.
Wave Washer
4. Remove the wave washer from the end of the end of the stub axle.
CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the
ground or the weight of the vehicle is allowed to be supported by the tires.
5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to
hub nut.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 4815
Front Disc Brake Caliper Attaching Bolts
6. Remove the 2 front disc brake caliper to steering knuckle attaching bolts.
Brake Caliper Mounting To Steering Knuckle
7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle and then
removing bottom of caliper out from under machined abutment on steering knuckle.
Correctly Supported Disc Brake Caliper
8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut
assembly. Do not allow the brake caliper assembly to
hang by the brake flex hose.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 4816
Remove/Install Brake Rotor
9. Remove the brake rotor from the hub and bearing assembly.
Removing Tie Rod End Attaching Nut
10. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod
end using the following procedure, hold tie rod end
stud with a 11/32 socket while loosening and removing nut with a wrench.
Tie Rod End Removal From Steering Knuckle Arm
11. Remove tie rod end from steering knuckle using Remover, Special Tool MB-991113.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 4817
Front Wheel Speed Sensor
12. Remove the front wheel speed sensor from the steering knuckle.
Wheel Stop Location On Steering Knuckle
13. If equipped, remove the wheel stop from the steering knuckle. When installing the pinch bolt
when assembling the steering knuckle to the ball joint
, the pinch bolt must be installed from the rear facing the front on the vehicle.
Control Arm To Steering Knuckle Attachment
14. Remove the steering knuckle to ball joint stud, clamping nut and bolt from the steering knuckle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 4818
Separating Ball Joint Stud From Steering Knuckle
15. Using a pry bar, separate steering knuckle from ball joint stud. Note: Use caution when
separating ball joint stud from steering knuckle, so ball
joint seal does not get cut.
NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly
in steering knuckle, end of driveshaft must be supported.
Steering Knuckle Separation From Driveshaft
16. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft
assembly.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during removal. Remove nuts while holding bolts stationary in the steering knuckles.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 4819
Fig. 21 Strut To Steering Knuckle Mounting Bolt Removal
17. Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts. 18. Remove the
steering knuckle from the strut.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 4820
Front Steering Knuckle: Service and Repair Installation
INSTALLATION
1. Transfer, or install if necessary, a new hub/bearing assembly into the steering knuckle. Refer to
Hub And Bearing Assembly Service.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during installation. Install nuts while holding bolts stationary in the steering knuckles.
Correctly Installed Eccentric Attaching Bolt
CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts,
the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket.
2. Install steering knuckle back in clevis bracket of strut damper assembly. Install the strut damper
to steering knuckle attaching bolts. Tighten both
attaching bolts to a torque of 90 Nm (65 ft. lbs.) plus an additional 1/4 turn.
3. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the
stud of the ball joint assembly. 4. Install a new steering knuckle to ball joint stud, clamping bolt and
nut. Tighten the clamping bolt and nut to a torque of 145 Nm (105 ft. lbs.).
Torquing Tie Rod End Attaching Nut
5. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding
stud of tie rod end stationary using a 11/32
socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32
socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.).
6. Install braking disc on hub and bearing assembly. 7. Install disc brake caliper assembly on
steering knuckle. Caliper is installed by first sliding bottom of caliper under abutment on steering
knuckle,
and then rotating top of caliper against top abutment.
8. Install disc brake caliper assembly to steering knuckle attaching bolts. Tighten the disc brake
caliper assembly attaching bolts to a torque of 22 Nm
(195 inch. lbs.).
9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and
stub axle to hub/bearing assembly nut on stub axle
and securely tighten nut.
10. Install wheel speed sensor and mounting bolt on steering knuckle. Tighten the speed sensor
attaching bolt to a torque of 7 Nm (60 inch. lbs.). 11. Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the
required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm
(100 ft. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 4821
12. Lower vehicle.
Torquing Front Stub Axle To Hub Nut
13. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of
203 Nm (150 ft. lbs.) 14. Install the spring wave washer on the end of the stub axle. 15. Install the
hub nut lock, and a new cotter pin. Wrap cotter pin prongs tightly around the hub nut lock. 16. Set
front Toe on vehicle to required specification.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage
NUMBER: 19-005-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO
ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Power Steering Fluid Usage
MODELS:
1993 - 2003 (AB) Ram Van
1994 - 2004 (AN) Dakota
1994 - 2002 (BR/BE) Ram Pickup
2004 (CS) Pacifica
1998-2004 (DN) Durango
2002 - 2004 (DR) Ram Pickup
1996 - 2000 (GS) Chrysler Voyager (International Markets)
1995 - 2000 (JA) Cirrus/Stratus/Breeze
2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 - 2004 (KJ) Liberty
2002 - 2004 (KJ) Cherokee (International Markets)
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Voyager/Caravan
2002 (PG) Chrysler PT Cruiser (International Markets)
1995-2004 (PL) Neon
1997 - 2003 (PR) Prowler
2002 - 2004 (PT) Chrysler PT Cruiser
2001 - 2004 (RG) Chrysler Voyager (International Markets)
2001 - 2004 (RS) Town & Country/Caravan/Voyager
1993 - 2002 (SR) Viper/Viper Coupe
2001 - 2004 (ST) Sebring Coupe/Stratus Coupe
1997 - 2004 (TJ) Wrangler
2003 - 2004 (VA) Sprinter
1999 - 2004 (WG) Grand Cherokee (International Markets)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4827
1999-2004 (WJ) Grand Cherokee
2003 - 2004 (ZB) Viper
2004 (ZH) Crossfire
DISCUSSION:
The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4
(MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH
vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved
service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and
MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is
no longer an indication of fluid condition.
The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number
for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA.
MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On
some past models, MS9602 should be used as the replacement fluid. On these models, if a power
steering system is being serviced that results in a large fluid loss, such as a pump, hose or
gear/rack replacement, the complete system should be drained and filled with MS9602.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4828
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4829
NOTE:
This bulletin supersedes owner's and service manuals for the vehicles listed above that may state
to use MS9933 in the power steering system, and that may state not to use automatic transmission
fluid in the power steering system.
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Capacity Specifications
Power Steering Fluid: Capacity Specifications
Power steering fluid 1.7 pt (US)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Capacity Specifications > Page 4832
Power Steering Fluid: Fluid Type Specifications
All models Mopar Power Steering Fluid or equivalent
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Page 4833
Power Steering Fluid: Service Precautions
DO NOT use automatic transmission fluid instead of Mopar Power Steering Fluid. System damage
can result.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Page 4834
Power Steering Fluid: Service and Repair
WARNING: FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING PARTS.
CAUTION: Do not use automatic transmission fluid in the power steering system.
Before removing the power steering filler cap, wipe the reservoir filler cap free of dirt and debris.
Remove the cap and check the fluid level on its dipstick. The dipstick should indicate COLD when
the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F). Do not
overfill the power steering system. Use only Mopar Power Steering Fluid, or an equivalent.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Description and Operation
Power Steering Fluid Reservoir: Description and Operation
All vehicles use a remote mounted reservoir for the power steering fluid. The power steering fluid
remote reservoir is mounted to the right fender shield under the hood.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Description and Operation > Page 4838
Power Steering Fluid Reservoir: Service and Repair
REMOVE
Remote Power Steering Fluid Reservoir
1. Remove the filler cap from remote power steering fluid reservoir. 2. Raise vehicle on jack stands
or centered on a frame contact type hoist. 3. Remove at power steering pump, the power steering
fluid hose coming from the power steering fluid reservoir. Let the power steering fluid drain
out of the reservoir and hose.
4. Lower vehicle. 5. Remove the fluid supply hose from the remote power steering fluid reservoir. 6.
Remove the 2 mounting screws attaching the remote fluid reservoir to the inner fender. 7. Remove
remote reservoir from inner fender.
INSTALL
1. Install remote power steering fluid reservoir on inner fender, by first inserting tab on reservoir into
hole in inner fender. Then rotate reservoir so
mounting tabs are against inner fender.
2. Install and securely tighten the 2 reservoir mounting screws.
Power Steering Fluid Hose Routing Clip
CAUTION: The power steering fluid reservoir to power steering pump supply hose must be routed
tightly against the strut tower and parallel to the dash panel. It must also be routed under the wiring
harness and below the drip tube. This will prevent the hose from coming in contact with the
accessory drive belt. The power steering fluid supply hose must be located in its correct position by
clipping it to the stud in the strut tower.
3. Install the fluid supply hose onto the power steering fluid reservoir fitting. Install the hose clamp
on the fluid supply hose at the fluid reservoir. Be
sure hose clamp is installed past bead on fluid reservoir fitting.
4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Install power steering
fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose at the
power steering pump. Be
sure hose clamp is installed past bead on pump fitting.
6. Lower vehicle. 7. Install routing clip for power steering fluid supply hose on stud in strut tower. 8.
Fill the remote fluid reservoir to the proper level and let the fluid settle for at least two 2 minutes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Description and Operation > Page 4839
9. Start the engine and let run for a few seconds. Then turn the engine off.
10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after
running the engine. 11. Raise the front wheels off the ground. 12. Start the engine. Slowly turn the
steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if
necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the
engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the
vehicle to stand a few minutes and repeat the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug
> 98 > Power Steering - Honk Or Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug
> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4848
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
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Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
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> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4849
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
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Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug
> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4850
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
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Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
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> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4851
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
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Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
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> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4852
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
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> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4853
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
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Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
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19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
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19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4859
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
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8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
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NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
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19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4862
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
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7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
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19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 4864
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Page 4865
Power Steering Line/Hose: Specifications
Hose Tube Nuts ...................................................................................................................................
................................................ 31 Nm (275 inch lbs.) Routing Bracket To Suspension Cradle
.................................................................................................................................................... 28
Nm (21 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Page 4866
Power Steering Line/Hose: Description and Operation
Power Steering Hoses
The power steering fluid hoses connect the components of the power steering system. They
transfer fluid from one component to the next. The power steering fluid supply hose is a formed
hose that connects the power steering fluid reservoir to the power steering pump. It is secured at
both ends using standard adjustable clamps. The power steering fluid pressure hose is a high
pressure hose that connects the power steering pump to the gear. At both ends of the flexible hose
portion are steel fittings that are pressure crimped to the flexible hose. A standard tube nut fitting
with an O-ring is used at both ends to connect the components. The power steering fluid return
hose is a formed metal and rubber hose that connects the gear back to the power steering pump. A
standard tube nut fitting with an O-ring is used to connect it to the gear. It is secured to the power
steering pump using a standard adjustable clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump
Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump
REMOVE
Fluid Supply Hose At Power Steering Fluid Reservoir
1. Remove the filler cap from remote power steering fluid reservoir. 2. Using a siphon pump,
remove as much power steering fluid as possible from the power steering fluid reservoir.
Power Steering Fluid Hose Routing Clip
3. Remove power steering fluid supply hose routing clip from stud in strut tower. 4. Raise vehicle
on jack stands or centered on a frame contact type hoist. 5. Remove at power steering pump, the
power steering fluid hose coming from the power steering fluid reservoir. Let the power steering
fluid drain
out of the reservoir and hose.
6. Lower vehicle. 7. Remove hose clamp attaching the power steering fluid supply hose to the
power steering fluid reservoir. 8. Remove the power steering fluid supply hose from the vehicle.
Hose is removed from the top of the engine compartment.
INSTALL
CAUTION: On V-6 engine applications, the power steering fluid reservoir to power steering hose
must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed
under the wiring harness and below the drip tube. This routing will prevent the power steering fluid
supply hose from coming in contact with the accessory drive belt.
1. Install and correctly route the power steering fluid supply hose from remote fluid reservoir down
to power steering pump. 2. Install the fluid supply hose onto the power steering fluid reservoir.
Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed
past bead on fluid reservoir fitting.
3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Install power steering
fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose. Be sure
hose clamp is installed
past bead on pump fitting.
5. Lower vehicle. 6. Install routing clip on power steering fluid supply hose. Be sure routing clip is
installed in a position to correctly align with stud in strut tower.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4869
7. Install routing clip for power steering fluid supply hose on stud in strut tower. 8. Fill the remote
fluid reservoir to the proper level and let the fluid settle for at least two minutes. 9. Start the engine
and let run for a few seconds. Then turn the engine off.
10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after
running the engine. 11. Raise the front wheels off the ground. 12. Start the engine. Slowly turn the
steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if
necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the
engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the
vehicle to stand a few minutes and repeat the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4870
Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose
Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power
steering pump fittings and steering gear ports to prevent entry of foreign material into the
components.
WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY
LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST
MANIFOLD OR CATALYST.
For part reference and part location for the vehicle that is being serviced, refer to the illustrations.
These show the hose bracket locations, hose routings and fitting locations by the engine
application of the vehicle. Use these images when referring to the removal or installation
procedures for the power steering hoses listed below.
REMOVE
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil
drain pan under vehicle to catch power steering fluid.
4. Raise the heat sleeve on the power steering fluid return hose to expose the return hose to steel
tube connection. Remove the hose clamp from the
power steering fluid return hose. Remove power steering fluid return hose from steel tube and
allow power steering fluid to drain from pump.
Pressure Hose Connection To Power Steering Pump
5. Remove the power steering fluid pressure line from the power steering pump pressure fitting.
Drain excess power steering fluid from hose.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4871
6. Remove bolt, attaching power steering hose routing bracket to front suspension cradle.
7. Disconnect power steering hose at power steering gear assembly. Drain the power steering fluid
from power steering pump and hose. 8. Discard the O-rings on the ends of power steering fluid
pressure hose.
INSTALL
1. Using a lint free towel, wipe clean the open power steering hose ends, power steering pump
pressure fitting and steering gear ports. 2. Install new O-rings on the ends of the power steering
fluid pressure hose. Lubricate O-rings using clean power steering fluid. 3. Attach the power
steering pressure hose to the fittings on the power steering pump and steering gear. Route hose
avoiding tight bends or kinking.
Do not bend tube ends of the power steering hoses when installing.
4. Install the power steering fluid hoses to suspension cradle routing bracket. Power steering fluid
hoses must remain away from the exhaust system
and must not come in contact with any unfriendly surfaces of the vehicle.
CAUTION: When tightening and torquing the pressure hose at the power steering pump, the
pressure hose is to be rotated against the fluid return hose fitting on the pump.
5. Tighten all fasteners shown for specific applications to their correct torques listed below:
- Pump End Tube Nut 34 Nm (25 ft. lbs.)
- Gear End Tube Nut 34 Nm (25 ft. lbs.)
- Pump Bracket Nut 40 Nm (30 ft. lbs.)
6. Install the power steering fluid return hose on the steel tube at the front suspension cradle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4872
7. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 Nm (18 inch. lbs.).
CAUTION: The protective heat sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses.
8. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses
to keep them in their proper position.
9. After hoses are installed and power steering system is filled with fluid and cap is installed on
reservoir. Start the engine and check for leaks.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 4873
Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose
Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power
steering pump fittings and steering gear ports to prevent entry of foreign material into the
components.
WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY
LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST
MANIFOLD OR CATALYST.
For part reference and part location for the vehicle that is being serviced, refer to the images.
These show the hose bracket locations, hose routings and fitting locations by the engine
application of the vehicle.
REMOVE
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil
drain pan under vehicle to catch power steering fluid.
4. Raise the insulating heat sleeve on the power steering hoses to expose the hose to steel tube
connection. Remove hose clamp where rubber portion
of power steering fluid return hose attaches to steel tube on suspension cradle. Remove rubber
hose from steel tube and allow power steering fluid to drain from pump.
5. Remove the power steering fluid return hose from the power steering pump return hose fitting.
INSTALL
1. Using a lint free towel, wipe clean the open power steering hose ends and power steering pump
fitting. 2. Attach the power steering return hose to the fitting on the power steering pump. Route
hose smoothly avoiding tight bends or kinking. Hose must
remain away from the exhaust system and not come in contact with any unfriendly surfaces of the
vehicle.
3. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 4.
Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 Nm (18 inch. lbs.).
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses. This is to prevent
overheating of the power steering fluid hoses.
5. When used, position the protective heat sleeves on the power steering hoses so they cover the
connection to the power steering pump. Then, tie
strap the heat sleeves to the power steering hoses to keep them in their proper position.
6. After hoses are installed and power steering system is filled with fluid and cap is installed on
reservoir. Start the engine and check for leaks.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage
Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage
NUMBER: 19-005-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO
ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Power Steering Fluid Usage
MODELS:
1993 - 2003 (AB) Ram Van
1994 - 2004 (AN) Dakota
1994 - 2002 (BR/BE) Ram Pickup
2004 (CS) Pacifica
1998-2004 (DN) Durango
2002 - 2004 (DR) Ram Pickup
1996 - 2000 (GS) Chrysler Voyager (International Markets)
1995 - 2000 (JA) Cirrus/Stratus/Breeze
2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 - 2004 (KJ) Liberty
2002 - 2004 (KJ) Cherokee (International Markets)
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Voyager/Caravan
2002 (PG) Chrysler PT Cruiser (International Markets)
1995-2004 (PL) Neon
1997 - 2003 (PR) Prowler
2002 - 2004 (PT) Chrysler PT Cruiser
2001 - 2004 (RG) Chrysler Voyager (International Markets)
2001 - 2004 (RS) Town & Country/Caravan/Voyager
1993 - 2002 (SR) Viper/Viper Coupe
2001 - 2004 (ST) Sebring Coupe/Stratus Coupe
1997 - 2004 (TJ) Wrangler
2003 - 2004 (VA) Sprinter
1999 - 2004 (WG) Grand Cherokee (International Markets)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4878
1999-2004 (WJ) Grand Cherokee
2003 - 2004 (ZB) Viper
2004 (ZH) Crossfire
DISCUSSION:
The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4
(MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH
vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved
service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and
MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is
no longer an indication of fluid condition.
The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number
for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA.
MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On
some past models, MS9602 should be used as the replacement fluid. On these models, if a power
steering system is being serviced that results in a large fluid loss, such as a pump, hose or
gear/rack replacement, the complete system should be drained and filled with MS9602.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4879
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 4880
NOTE:
This bulletin supersedes owner's and service manuals for the vehicles listed above that may state
to use MS9933 in the power steering system, and that may state not to use automatic transmission
fluid in the power steering system.
POLICY: Information Only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Mechanical Specifications
Power Steering Pump: Mechanical Specifications
Flow Control Valve Fitting ....................................................................................................................
................................................... 75 Nm (55 ft. lbs.) Mounting Bolts ...................................................
...................................................................................................................................... 54 Nm (40 ft.
lbs.) Rear Bracket To Engine Mounting Bolts
.................................................................................................................................................. 54 Nm
(40 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Mechanical Specifications > Page 4883
Power Steering Pump: Pressure, Vacuum and Temperature Specifications
Flow at 1500 RPM & Min. Pressure
............................................................................................................................ 5.0 - 7.0 Liters/Min
(1.3 - 1.9 GPM) Control Valve Pressure Relief
....................................................................................................................................... 9653 - 10342
kPa (1400 - 1500 psi)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 4884
Power Steering Pump: Service Precautions
WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY
LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST
MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT
PERSONAL INJURY FROM MOVING PARTS.
CAUTION: When the system is open, cap all open ends of the hoses, power steering pump fittings
or power steering gear ports to prevent entry of foreign material into the components.
NOTE: Do not use any type of automatic transmission fluid in the power steering system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 4885
Power Steering Pump: Description and Operation
Hydraulic pressure for the operation of the power steering gear is provided by a belt driven power
steering pump. The power steering pump is a constant flow rate and displacement vane type
pump. The power steering pump used on all applications is the Vane-Submerged remote reservoir
style power steering pump. The remote reservoir type pump has the pump housing and internal
components combined with the fluid housing. But it has a remote reservoir for the power steering
fluid supply. The power steering pump is mounted on the back side of the engine and is accessed
from underneath the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Initial Operation
Power Steering Pump: Service and Repair Power Steering Pump Initial Operation
CAUTION: The fluid level should be checked with engine off to prevent injury from moving
components. Use only Mopar(R) Power Steering Fluid. Do not use automatic transmission fluid. Do
not overfill.
Wipe filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the
fluid is at normal temperature of approximately 21°C to 27°C (70°F to 80°F). 1. Fill the pump fluid
reservoir to the proper level and let the fluid settle for at least two 2 minutes. 2. Start the engine
and let run for a few seconds. Then turn the engine off. 3. Add fluid if necessary. Repeat the above
procedure until the fluid level remains constant after running the engine. 4. Raise the front wheels
off the ground. 5. Start the engine. Slowly turn the steering wheel right and left, lightly contacting
the wheel stops. 6. Add power steering fluid if necessary. 7. Lower the vehicle and turn the steering
wheel slowly from lock to lock. 8. Stop the engine. Check the fluid level and refill as required. 9. If
the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above
procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Initial Operation > Page 4888
Power Steering Pump: Service and Repair Power Steering Pump Overhaul
The only serviceable part of the power steering pump is the pulley. The procedure following is for
removal and installation of the pulley from the pump once the pump is removed from the vehicle.
DISASSEMBLY
1. Remove the power steering pump from the vehicle.
2. Remove the pulley from the shaft of the power steering pump using Puller C-4333 or C-4068.
CAUTION: Do not hammer on power steering pump pulley. This will damage the pulley and the
power steering pump.
3. Replace pulley if it is found to be bent, cracked, or loose.
ASSEMBLY
1. Install the pulley with Installer C-4063. Do not use the tool adapters. 2. Ensure that the tool and
the pulley remain aligned with the pump shaft. Prevent the pulley from being cocked on the shaft.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Initial Operation > Page 4889
Pulley To Pump Shaft Location
3. Install the pulley until it is flush with the end of the power steering pump shaft. 4. Install the
power steering pump on the vehicle.
NOTE: Once the pump is installed on the vehicle, run the engine until warm (5 min.) and note any
belt chirp. If chirp exists, move the pulley outward approximately 0.5 mm (0.020 inch). If noise
increases, press the pulley on 1.0 mm (0.040 inch). Be careful that the pulley does not contact the
pump mounting bolts.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Initial Operation > Page 4890
Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation
Installation
INSTALLATION
1. Install power steering pump back in vehicle using the reverse order of its removal through the
exhaust tunnel of the vehicle. 2. Install the power steering pump on its mounting bracket. Install the
3 power steering pump mounting bolts. Tighten the power steering pump
mounting bolts to a torque of 54 Nm (40 ft. lbs.).
3. Install the support bracket attaching rear of power steering pump to engine. Tighten the nut and
bolt holding the strut assembly to bracket and the
intake manifold stud to a torque of 54 Nm (40 ft. lbs).
NOTE: Before installing power steering pressure hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage and replace if required.
4. Install the power steering fluid pressure line onto the output fitting of the power steering pump.
Tighten the pressure line to pump fitting tube nut
to a torque of 31 Nm (275 inch. lbs.).
5. Install the power steering fluid, low pressure return hose on the power steering pump low
pressure fitting. Be sure hose clamps are properly
reinstalled.
6. Install the power steering fluid supply hose from the power steering fluid reservoir, on the power
steering pump fluid fitting. Be sure hose is clear
of accessory drive belts and all hose clamps are properly reinstalled.
7. Install the serpentine drive belt. 8. Install the power steering fluid return hose on the steel tube at
the front suspension cradle. 9. Install a screw type hose clamp on the power steering hose to steel
tube connection. Be sure hose clamps are properly reinstalled. Tighten the
screw clamp to a torque of 2 Nm (18 inch. lbs.).
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses. This is required to
keep the power steering hoses from becoming overheated.
10. When used, properly position the protective heat sleeves on the power steering hoses. Then,
tie strap the heat sleeves to the power steering hoses
to keep them in their proper position.
11. Install the exhaust pipe on the exhaust manifold. Install all exhaust system hangers/isolators on
the exhaust system brackets. 12. Connect the oxygen sensor wiring harness to the vehicle wiring
harness. Install wiring harness grommet in the floor pan of the vehicle. 13. Install the accessory
drive splash shield. 14. Lower vehicle. 15. Connect the negative battery cable on the negative
battery post. 16. Perform the POWER STEERING PUMP INITIAL OPERATION service procedure
listed to properly fill and bleed the power steering system. 17. Inspect for leaks.
Removal
NOTE: Before proceeding with this procedure, review the Service Precautions.
REMOVAL
1. Remove the (-) negative battery cable from the battery and isolate cable. 2. Remove cap from
power steering fluid reservoir. 3. Using a siphon pump, remove as much power steering fluid as
possible from the power steering fluid reservoir. 4. Raise vehicle on jack stands or centered on a
frame contact type hoist. 5. Disconnect the oxygen sensor wiring harness from the vehicle wiring
harness. Access to connection at vehicle wiring harness is through the
oxygen sensor wiring harness grommet in the floor pan of the vehicle.
NOTE: The exhaust system needs to be removed from the engine to allow for an area to remove
the power steering pump from the vehicle.
6. Remove the catalytic converter from the exhaust manifold. Then remove all the exhaust system
hangers/isolators from the brackets on the exhaust
system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Initial Operation > Page 4891
7. Move the exhaust system as far rearward and to the left side of the vehicle as possible.
Power Steering Return Hose At Return Line
8. Raise the heat sleeve on the power steering hoses to expose the hose to steel tube connection.
Remove the hose from the power steering fluid
return line on the front suspension cradle. Allow the remaining power steering fluid to drain from the
pump and fluid reservoir through the removed return hose.
9. Remove the accessory drive splash shield.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Initial Operation > Page 4892
Serpentine Drive Belt And Routing
10. Remove the serpentine accessory drive belt from the engine.
Power Steering Hoses
11. Remove the power steering fluid supply hose coming from the remote fluid reservoir, from the
fitting on the power steering pump. Drain off
excess power steering fluid from hose.
12. Remove the power steering fluid pressure line from the power steering pump. Drain excess
power steering fluid from tube. 13. Remove the power steering fluid return hose from the power
steering pump. Drain excess power steering fluid from tube.
Power Steering Pump Support Bracket
14. Remove the support bracket at the rear of the power steering pump attaching the pump to the
rear of the engine.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Initial Operation > Page 4893
15. Remove the 3 bolts mounting the power steering pump to the alternator/power steering pump
and belt tensioner mounting bracket. 16. Remove the power steering pump from its mounting
bracket. 17. The power steering pump is removed from the vehicle by pulling it out through the
exhaust tunnel area in the floor pan of the vehicle. 18. If transferal of the power steering pump
pulley is necessary, refer to Overhaul.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Tools and Equipment > Power Steering Pump Pulley Puller C-4333
Special Tool C-4333
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Tools and Equipment > Power Steering Pump Pulley Puller C-4333 > Page 4896
Special Tool C-4063B
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming > Page 4902
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
Negative Battery Cable
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering
column and at the lower edge of the lower instrument
panel.
2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the
proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative
terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and
record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any
diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper
Body
Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes
on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to
diagnose the problem.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover >
Component Information > Service and Repair
Steering Column Cover: Service and Repair
REMOVAL
Park Brake Release Handle
1. Remove screws holding parking brake release handle to instrument panel.
Lower Steering Column Cover
2. Remove screws holding bottom of lower steering column cover to instrument panel. 3. Remove
screw holding right side of lower steering column cover to instrument panel.
Park Brake Release Handle
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover >
Component Information > Service and Repair > Page 4906
4. Disengage park brake release cable case from groove on end of release handle. 5. Disengage
cable end pivot from slot on release handle.
INSTALLATION
For installation, reverse the above procedures,
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering
Column - Pop/Tick From Steering Wheel Area
Technical Service Bulletin # 19-003-03 Date: 030829
Steering Column - Pop/Tick From Steering Wheel Area
NUMBER: 19-003-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-008-01, DATED NOV. 23, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**. THE REVISION INCLUDES AN ADDED NOTE AND A REVISED NOTE
CORRECTING VEHICLE BUILD DATES.
SUBJECT: Pop/Tick Sound In Steering Wheel Area
OVERVIEW: This bulletin involves installing a shim package and a tilt head housing assembly in
the steering column upper tilt head.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
2001 - 2002 (RG) Chrysler Voyager (International Markets)
1999 - 2002 (WJ) Grand Cherokee
2001 - 2002 (WG) Grand Cherokee (International Markets)
NOTE:
**This bulletin applies to vehicles equipped with tilt steering (sales code SUA) built on or before
Jan. 13, 2002 (MDH 0113XX).**
NOTE:
**For vehicles built on or after Jan. 14, 2002 refer to service bulletin 19-001-03 dated Feb. 7,
2003.**
SYMPTOM/CONDITION:
A pop/tick sound may be heard coming from the steering wheel area while the vehicle is in motion.
The sound is associated with input from the road surface. It may be difficult to readily repeat the
sound once it has occurred until additional road input is experienced, such as driving over an
expansion strip.
DIAGNOSIS:
If the vehicle exhibits the Symptom/Condition, perform the Repair Procedure.
NOTE:
If the symptom is experienced on 1996 - 2000 NS or GS vehicles, Service Bulletin (SB) 19-09-99
(Click/Rattle Sound in Area of Steering Wheel) should be performed in conjunction with this
bulletin.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering
Column - Pop/Tick From Steering Wheel Area > Page 4915
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Repair Procedure
1. Make sure the front wheels of the vehicle are in the STRAIGHT AHEAD position before
beginning steering wheel removal procedure.
WARNING:
Remove and isolate the negative battery cable from the vehicle battery. This is the only sure way to
disable the air bag system. Failure to do this could result in accidental air bag deployment and
possible personal injury.
2. Remove and isolate the negative battery cable from the battery.
3. Remove the lower and upper steering column shrouds.
4. Remove the driver's air bag from the steering wheel. Disconnect the clock spring, speed control
(if equipped), and radio control (if equipped) wiring connections.
5. Remove the steering wheel attaching nut.
6. Using the appropriate steering wheel puller, remove the steering wheel.
7. Remove the multi-function switch and its wiring connections.
8. Disconnect the clock spring wiring connection and remove the clock spring.
NOTE:
When removing the clock spring, do not change the orientation of the clock spring inner wheel. If
the orientation of the clock spring inner wheel is changed, the clock spring will have to be centered.
Follow the procedure for clock spring centering in the appropriate service manual.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering
Column - Pop/Tick From Steering Wheel Area > Page 4916
9. Using needle nose pliers, remove both tilt head return springs from the tilt head assembly.
10. Remove the snap ring from the steering shaft upper tilt head assembly.
11. Remove the two # 25 torx bit screws attaching the tilt rack to the tilt head housing.
12. Remove the two # 45 torx bit screws attaching the tilt head assembly to the steering column.
13. Lift tilt steering column lever and remove the tilt head housing and the tilt rack from the steering
column.
14. Remove the tilt head housing from the shaft being careful not to misplace the lower bearing
wedge.
15. Remove and discard the wave washer.
16. To the base of the shaft, install in order: the shim, the wave washer, and the lower bearing
wedge (Fig. 1).
17. Install the new tilt head assembly to the steering shaft. Apply Mopar Lock & Seal adhesive (or
equivalent) to both torx screw threads only and tighten to 11 N.m (100 in. lbs.).
18. Install the upper bearing wedge to the tilt steering shaft.
19. Apply a light coat of Mopar silicon spray lubricant on the steering shaft near the snap ring
groove. This will facilitate snap ring installation.
20. Position the new snap ring onto the shaft near the bearing wedge. With one hand, pull the
steering shaft outward and push the snap ring as far down the shaft as possible.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering
Column - Pop/Tick From Steering Wheel Area > Page 4917
21. From the parts package, use special tool 05083385AA (Installer) and place it over the steering
shaft so the one edge of the tool is resting on the snap ring (Fig. 2).
22. Thread the steering wheel nut onto the steering shaft and against the edge of Special Tool
05083385AA. Tighten the steering wheel nut to 16 N.m (12 ft. lbs.) This will slide the snap ring into
its groove on the steering shaft.
NOTE:
Do not over torque steering wheel nut.
NOTE:
Make sure the snap ring is fully seated into its groove. Once the repair is complete, tool
05083385AA can be discarded.
23. Make sure that the snap ring is fully seated into its groove.
24. Lift the tilt lever and slide the tilt head rack into position. Apply Mopar Lock and Seal adhesive
to the torx screw threads and install the torx screws and tighten to 6 N.m (50 in. lbs.).
25. Install the clock spring and its wiring connections.
26. Install the multi-function switch and its wiring connections.
27. Install the steering wheel and tighten steering wheel nut to 61 N.m (45 ft. lbs.).
28. Connect the clock spring, speed control (if equipped), and radio control (if equipped) wiring
connections.
29. Install driver's air bag and tighten screws to 10 N.m (90 in. lbs.).
30. Install the lower and upper steering column shrouds.
31. Connect negative battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 >
Steering Column - Pop/Tick From Steering Wheel Area
Technical Service Bulletin # 19-003-03 Date: 030829
Steering Column - Pop/Tick From Steering Wheel Area
NUMBER: 19-003-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-008-01, DATED NOV. 23, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**. THE REVISION INCLUDES AN ADDED NOTE AND A REVISED NOTE
CORRECTING VEHICLE BUILD DATES.
SUBJECT: Pop/Tick Sound In Steering Wheel Area
OVERVIEW: This bulletin involves installing a shim package and a tilt head housing assembly in
the steering column upper tilt head.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
2001 - 2002 (RG) Chrysler Voyager (International Markets)
1999 - 2002 (WJ) Grand Cherokee
2001 - 2002 (WG) Grand Cherokee (International Markets)
NOTE:
**This bulletin applies to vehicles equipped with tilt steering (sales code SUA) built on or before
Jan. 13, 2002 (MDH 0113XX).**
NOTE:
**For vehicles built on or after Jan. 14, 2002 refer to service bulletin 19-001-03 dated Feb. 7,
2003.**
SYMPTOM/CONDITION:
A pop/tick sound may be heard coming from the steering wheel area while the vehicle is in motion.
The sound is associated with input from the road surface. It may be difficult to readily repeat the
sound once it has occurred until additional road input is experienced, such as driving over an
expansion strip.
DIAGNOSIS:
If the vehicle exhibits the Symptom/Condition, perform the Repair Procedure.
NOTE:
If the symptom is experienced on 1996 - 2000 NS or GS vehicles, Service Bulletin (SB) 19-09-99
(Click/Rattle Sound in Area of Steering Wheel) should be performed in conjunction with this
bulletin.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 >
Steering Column - Pop/Tick From Steering Wheel Area > Page 4923
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Repair Procedure
1. Make sure the front wheels of the vehicle are in the STRAIGHT AHEAD position before
beginning steering wheel removal procedure.
WARNING:
Remove and isolate the negative battery cable from the vehicle battery. This is the only sure way to
disable the air bag system. Failure to do this could result in accidental air bag deployment and
possible personal injury.
2. Remove and isolate the negative battery cable from the battery.
3. Remove the lower and upper steering column shrouds.
4. Remove the driver's air bag from the steering wheel. Disconnect the clock spring, speed control
(if equipped), and radio control (if equipped) wiring connections.
5. Remove the steering wheel attaching nut.
6. Using the appropriate steering wheel puller, remove the steering wheel.
7. Remove the multi-function switch and its wiring connections.
8. Disconnect the clock spring wiring connection and remove the clock spring.
NOTE:
When removing the clock spring, do not change the orientation of the clock spring inner wheel. If
the orientation of the clock spring inner wheel is changed, the clock spring will have to be centered.
Follow the procedure for clock spring centering in the appropriate service manual.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 >
Steering Column - Pop/Tick From Steering Wheel Area > Page 4924
9. Using needle nose pliers, remove both tilt head return springs from the tilt head assembly.
10. Remove the snap ring from the steering shaft upper tilt head assembly.
11. Remove the two # 25 torx bit screws attaching the tilt rack to the tilt head housing.
12. Remove the two # 45 torx bit screws attaching the tilt head assembly to the steering column.
13. Lift tilt steering column lever and remove the tilt head housing and the tilt rack from the steering
column.
14. Remove the tilt head housing from the shaft being careful not to misplace the lower bearing
wedge.
15. Remove and discard the wave washer.
16. To the base of the shaft, install in order: the shim, the wave washer, and the lower bearing
wedge (Fig. 1).
17. Install the new tilt head assembly to the steering shaft. Apply Mopar Lock & Seal adhesive (or
equivalent) to both torx screw threads only and tighten to 11 N.m (100 in. lbs.).
18. Install the upper bearing wedge to the tilt steering shaft.
19. Apply a light coat of Mopar silicon spray lubricant on the steering shaft near the snap ring
groove. This will facilitate snap ring installation.
20. Position the new snap ring onto the shaft near the bearing wedge. With one hand, pull the
steering shaft outward and push the snap ring as far down the shaft as possible.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 >
Steering Column - Pop/Tick From Steering Wheel Area > Page 4925
21. From the parts package, use special tool 05083385AA (Installer) and place it over the steering
shaft so the one edge of the tool is resting on the snap ring (Fig. 2).
22. Thread the steering wheel nut onto the steering shaft and against the edge of Special Tool
05083385AA. Tighten the steering wheel nut to 16 N.m (12 ft. lbs.) This will slide the snap ring into
its groove on the steering shaft.
NOTE:
Do not over torque steering wheel nut.
NOTE:
Make sure the snap ring is fully seated into its groove. Once the repair is complete, tool
05083385AA can be discarded.
23. Make sure that the snap ring is fully seated into its groove.
24. Lift the tilt lever and slide the tilt head rack into position. Apply Mopar Lock and Seal adhesive
to the torx screw threads and install the torx screws and tighten to 6 N.m (50 in. lbs.).
25. Install the clock spring and its wiring connections.
26. Install the multi-function switch and its wiring connections.
27. Install the steering wheel and tighten steering wheel nut to 61 N.m (45 ft. lbs.).
28. Connect the clock spring, speed control (if equipped), and radio control (if equipped) wiring
connections.
29. Install driver's air bag and tighten screws to 10 N.m (90 in. lbs.).
30. Install the lower and upper steering column shrouds.
31. Connect negative battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 4934
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 4935
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 4936
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 4937
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 4938
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 4939
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear
Removal/Installation Revisions
Steering Gear: All Technical Service Bulletins Steering - Steering Gear Removal/Installation
Revisions
NUMBER: 26-07-99A
GROUP: Miscellaneous
DATE: July, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revisions to the steering gear removal and installation procedures
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear
Removal/Installation Revisions > Page 4945
19-28
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear
Removal/Installation Revisions > Page 4946
19-29
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear
Removal/Installation Revisions > Page 4947
19-30
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 4952
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 4953
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 4954
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 4955
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 4956
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 4957
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear
Removal/Installation Revisions
Steering Gear: All Technical Service Bulletins Steering - Steering Gear Removal/Installation
Revisions
NUMBER: 26-07-99A
GROUP: Miscellaneous
DATE: July, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revisions to the steering gear removal and installation procedures
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear
Removal/Installation Revisions > Page 4963
19-28
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear
Removal/Installation Revisions > Page 4964
19-29
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-07-99A > Jul > 99 > Steering - Steering Gear
Removal/Installation Revisions > Page 4965
19-30
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Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 4966
Steering Gear: Specifications
To Cradle Attaching Bolts ....................................................................................................................
................................................ 183 Nm (135 ft. lbs.) Coupler Pinch Bolt ............................................
.................................................................................................................................. 28 Nm (250 inch
lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 4967
Steering Gear: Service Precautions
WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY
LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST
MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT
PERSONAL INJURY FROM MOVING PARTS.
CAUTION: When the system is open, cap all open ends of the hoses, power steering pump fittings
or power steering gear ports to prevent entry of foreign material into the components.
NOTE: Do not use any type of automatic transmission fluid in the power steering system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 4968
Steering Gear: Description and Operation
Power Steering Gear Assembly
NOTE: The power steering gear should NOT be serviced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear should be replaced.
If a steering gear boot needs to be replaced due to damage, refer to the power steering gear for
proper procedure. The power steering system consists of these four major components. Power
Steering Gear, Power Steering Pump, Pressure Hose, and Return Line. Turning of the steering
wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack
teeth. Power assist steering is provided by an open center, rotary type control valve which directs
oil from the pump to either side of the integral rack piston. Road feel is controlled by the diameter of
a torsion bar which initially steers the vehicle. As required steering effort increases, as in a turn, the
torsion bar twists, causing relative rotary motion between the rotary valve body and the valve spool.
This movement directs oil behind the integral rack piston, which, in turn, builds up hydraulic
pressure and assists in the turning effort. The drive tangs on the pinion mate loosely with a stub
shaft to permit manual steering control to be maintained if the drive belt on the power steering
pump should break. However, under these conditions, steering effort will be increased.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal
Steering Gear: Service and Repair Removal
The content of this article reflects the changes called out by TSB 26-07-99.
NOTE:
- The power steering gear should not be serviced or adjusted. If a malfunction or oil leak occurs,
the complete steering gear assembly must be replaced.
- Before proceeding with this procedure, review the Service Precautions.
REMOVAL
CAUTION: Positioning the steering column in the locked position will prevent the clockspring from
being accidentally over-extended when the steering column is disconnected from the intermediate
steering coupler.
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir. 3. With the ignition key in
the locked position turn the steering wheel to the left until the steering wheel is in the locked
position.
4. With the vehicle on the ground, disconnect the steering column shaft coupler from the steering
gear intermediate coupler. 5. Raise vehicle on jack stands or centered on a frame contact type
hoist. 6. Remove the front tires.
Power Steering Return Hose At Return Line
7. Raise the heat sleeve on the power steering return hose to expose the return hose to steel tube
connection. Remove the return hose from the metal
tube of the power steering fluid return line. Then allow the remaining power steering fluid to drain
from the system through the hose and metal tube.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 4971
8. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod
end using the following procedure, hold tie rod end
stud with a 11/32 socket while loosening and removing nut with wrench.
Tie Rod End Removal From Steering Knuckle
9. Remove both tie rod ends from steering knuckles, using Puller Special Tool MB-990635 or
MB-991113.
HCU Bracket Attaching Bolts
10. Remove the 2 bolts and loosen the third attaching the antilock brakes hydraulic control unit
(HCU) to the front suspension cradle. Then rotate the
HCU rearward to allow access to the cradle plate attaching nut and bolt just forward of the HCU.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 4972
Front Suspension Cradle Plate and Attaching Bolts
11. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Then remove the cradle plate from the cradle. 12. If the vehicle is equipped with All Wheel
Drive, remove the power transfer unit.
Tube Bracket (FWD Shown)
13. Remove the bracket attaching the power steering fluid tubes to the front suspension cradle.
Power Steering Fluid Pressure and Return Hoses at Steering Gear
14. Using a 18mm crowfoot, remove the power steering fluid pressure and return lines from the
power steering gear.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 4973
15. Remove the 3 bolts and nuts mounting the steering gear to the front suspension cradle.
NOTE: The next step must be done to allow the removal of the steering gear from the front
suspension cradle. The steering gear can not be removed from the vehicle with the intermediate
coupler attached to the steering gear.
Removing Roll Pin From Intermediate Coupler
16. Lower steering gear from suspension cradle enough to allow access to the intermediate coupler
roll pin. Install Remover/Installer Special Tool
6831A through the center of the roll pin, securing with the knurled nut. Hold threaded rod stationary
while turning nut, this will pull the roll pin out of the intermediate coupler.
17. Separate the intermediate coupler from the shaft of the steering gear. 18. Remove the steering
gear assembly from the front suspension cradle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 4974
Steering Gear: Service and Repair Installation
The content of this article reflects the changes called out by TSB 26-07-99.
INSTALLATION
1. Install the steering gear up in the front suspension cradle, leaving room to install intermediate
coupler. 2. Start the roll pin into the intermediate coupler before installing coupler on steering gear
shaft. Start roll pin into coupler, using a hammer and
tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear.
Installing Roll Pin In Intermediate Coupler
3. Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing it with
the knurled nut. Hold threaded rod stationary
while turning nut, this will pull the roll pin into the intermediate coupler.
4. Install steering gear assembly on the front suspension cradle. Install the 3 steering gear to front
suspension cradle mounting bolts and nuts.
CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very
important.
5. Tighten the 3 steering gear to suspension cradle mounting bolts to a torque of 183 Nm (135 ft.
lbs.). 6. Attach the power steering fluid pressure and return lines to the proper fittings on the
steering gear. Tighten the power steering fluid line tube nuts
to a torque of 31 Nm (275 in. lbs.).
7. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto
stud of tie rod end. While holding stud of tie rod
end stationary using a 11/32 socket, tighten tie rod end to steering knuckle attaching nut. Then
using a crowfoot and 11/32 socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft.
lbs.).
8. If the vehicle is equipped with All Wheel Drive, install the power transfer unit.
CAUTION: Proper torque on the cradle plate to suspension cradle mounting bolts is very important.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 4975
9. Install cradle plate on front suspension cradle and install the 10 cradle plate to cradle attaching
bolts and nuts. Tighten all attaching bolts to a
torque of 165 Nm (123 ft. lbs.).
10. Install the bracket attaching the power steering fluid tubes to the front suspension cradle. 11.
Install the power steering fluid return hose on the steel tube at the front suspension cradle. 12.
Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose
clamp is installed on return tube past the upset
bead on the tube. Tighten the screw clamp to a torque of 2 Nm (18 in. lbs.).
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses. This is required to
prevent the power steering hoses from being overheated.
13. When used, properly position the protective heat sleeves on the power steering hoses. Then,
tie strap the heat sleeves to the power steering hoses
to keep them in their proper position.
14. Install the front tire and wheel assemblies on vehicle. Install the wheel lug nuts and torque to
129 Nm (95 ft. lbs.). 15. Lower the vehicle to a level were the interior of vehicle is accessible. 16.
Using the intermediate coupler, turn the front wheels of the vehicle to the left until the intermediate
coupler shaft is properly aligned with the
steering column coupler. Assemble the steering column shaft coupler onto the steering gear
intermediate coupler. Install steering column coupler to intermediate shaft retaining pinch bolt.
Tighten the pinch bolt nut to a torque of 28 Nm (250 in. lbs.).
17. Perform the POWER STEERING PUMP INITIAL OPERATION to properly fill and bleed the
power steering system. 18. Inspect for leaks. 19. Adjust front toe.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Page 4976
Steering Gear: Tools and Equipment
Remover Tie Rod End MB-991113
Special Tool 6831A
Special Tool C-4975A
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Specifications
Steering Wheel: Specifications
Retaining Nut .......................................................................................................................................
..................................................... 61 Nm (45 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Specifications
Tie Rod End: Specifications
Adjusting Sleeve Nut ...........................................................................................................................
..................................................... 75 Nm (55 ft. lbs.) To Steering Knuckle Nut ..................................
........................................................................................................................................ 54 Nm (40 ft.
lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Outer Tie Rod End
Tie Rod End: Service and Repair Outer Tie Rod End
REMOVAL
1. Loosen inner tie rod to outer tie rod jam nut.
2. Remove nut attaching outer tie rod end to steering knuckle. The nut is to be removed from tie
rod end by holding tie rod end stud with a 11/32
socket while loosening and removing nut with a wrench.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Outer Tie Rod End > Page 4986
Tie Rod End Removal From Steering Knuckle
3. Remove the tie rod end stud from steering knuckle arm, using Remover, Special Tool,
MB-991113 or MB-990635. 4. Remove outer tie rod end from inner tie rod by unthreading it from
the inner tie rod.
INSTALLATION
NOTE: Before installing the outer tie rod end, make sure the jam nut is on inner tie rod.
1. Install outer tie rod end onto inner tie rod. 2. Do not tighten jam nut.
3. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie
rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and
11/32 socket torque tie rod end attaching nut to 54 Nm (40 ft. lbs.).
4. Tighten tie rod jam nut to 55 Nm (75 ft. lbs.) torque.
CAUTION: During this procedure do not allow the steering gear boot to become twisted.
5. Adjust the front toe setting on the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Outer Tie Rod End > Page 4987
Tie Rod End: Service and Repair Inner Tie Rod End
The inner tie rod end is serviced with the rack and pinion assembly only. Chrysler does not provide
a separate service procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description
and Operation
Ball Joint: Description and Operation
Ball Joint Assembly
The ball joint is pressed into the lower control arm. The ball joint has a non-tapered stud with a
notch to provide clearance for the steering knuckle clamp bolt and to provide retention of the ball
stud in the steering knuckle. The ball joint stud is clamped and locked into the steering knuckle leg
using a pinch bolt. The ball joint is lubricated for life during the manufacturing process. Once
lubricated for life, the grease fitting head is snapped off by the manufacturer. This is done to
eliminate the possibility of lubrication latter during the ball joints life thus damaging the non-vented
seal boot. The ball joint used on this vehicle is replaceable and if found defective can be serviced
as a separate component of the lower control arm assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description
and Operation > Page 4992
Ball Joint: Testing and Inspection
With the weight of the vehicle resting on the road wheels, grasp the grease fitting (which from the
manufacturer should have the head missing) on the bottom of the ball joint and with no mechanical
assistance or added force attempt to rotate the grease fitting. If the ball joint is worn, the grease
fitting will rotate easily. If movement is noted, replacement of the ball joint is recommended.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint Replacement (Front Suspension)
Ball Joint: Service and Repair Ball Joint Replacement (Front Suspension)
REMOVE
Ball Joint Seal Boot Removal
1. Using a screw driver or other suitable tool, pry the seal boot off of the ball joint assembly.
Ball Joint Removal From Lower Control Arm
2. Position receiving cup, Special Tool 6758 to support lower control arm when removing ball joint
assembly. Install Remover, Special Tool 6919 on
top of the ball joint assembly.
3. Using the arbor press, press the ball joint assembly completely out of the lower control arm.
INSTALL
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint Replacement (Front Suspension) > Page 4995
Installation Position Of Ball Joint In Control Arm
NOTE: When installing ball joint in lower control arm, position the ball joint in control arm so notch
in ball joint stud is in the direction shown. This will ease assembly of the ball joint to the steering
when installing pinch bolt.
1. By hand, position ball joint into ball joint bore of lower control arm. Be sure ball joint is not
cocked in the bore of the control arm, this will cause
the ball joint to bind when being pressed into control arm.
Installing Ball Joint In Control Arm
2. Position control arm with installed ball joint, in an arbor press with Receiving Cup, Special Tool
6758 supporting the lower control arm. Then
center Installer, Special Tool 6908-4 on the bottom of the ball joint.
Correctly Installed Lower Ball Joint
3. Carefully align all pieces. Then press the ball joint into the lower control arm until it is completely
seated against surface of lower control arm. The
ball joint is correctly installed when there is no gap between the ball joint and the lower control arm.
Do not apply excessive force against the ball joint or the lower control arm.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint Replacement (Front Suspension) > Page 4996
CAUTION: When installing the ball joint seal on the ball joint/lower control arm, the shield on the
ball joint seal must be positioned as shown.
4. Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is
to he with the shield positioned.
CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the
sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed.
5. Place Installer, Special Tool 6758 over seal boot and squarely align it with bottom edge of seal
boot. Apply hand pressure to Special Tool 6758
until seal boot is pressed squarely against top surface of lower control arm.
CAUTION: A replacement ball joint is not prelubricated. Properly lubricate the replacement ball joint using
Mopar Multi-Mile grease or an equivalent. Lubricate ball joint after seal boot is installed but prior to
top of seal boot being pushed down below notch in ball joint stud. Air must vent out of the seal boot
at notch when grease is pumped into ball joint, failure to do so will balloon and damage seal boot.
Do not over grease the ball joint, this will prevent the seal boot from pushing down on the stud of
the ball joint.
- After the ball joint is properly greased, clip the end of the grease fitting off below the hex. The ball
joint seal boot is non-purgeable and further greasing is not required and can result in damage to
the seal boot.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint Replacement (Front Suspension) > Page 4997
Ball Joint: Service and Repair Seal Boot Replacement
REMOVE
Ball Joint Seal Boot Removal
1. Using a screw driver or other suitable tool, pry the seal boot off of the ball joint assembly.
INSTALL
Ball Joint Seal Boot Installed Position
CAUTION: When installing the ball joint seal on the ball joint/lower control arm, the shield on the
ball joint seal must be positioned as shown.
1. Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is
to be with the shield positioned.
CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the
sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint Replacement (Front Suspension) > Page 4998
2. Place Installer, Special Tool 6758 over seal boot and squarely align it with bottom edge of seal
boot. Apply hand pressure to Special Tool 6758
until seal boot is pressed squarely against top surface of lower control arm.
CAUTION: A replacement ball joint is not prelubricated. Properly lubricate the replacement ball joint using
Mopar Multi-Mile grease or an equivalent. Lubricate ball joint after seal boot is installed but prior to
top of seal boot being pushed down below notch in ball joint stud. Air must vent out of the seal boot
at notch when grease is pumped into ball joint, failure to do so will balloon and damage seal boot.
Do not over grease the ball joint, this will prevent the seal boot from pushing down on the stud of
the ball joint.
- After the ball joint is properly greased, clip the end of the grease fitting off below the hex. The ball
joint seal boot is non-purgeable and further greasing is not required and can result in damage to
the seal boot.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Service and Repair > Front
Control Arm Bushing: Service and Repair Front
REMOVE
1. Remove the lower control arm from the front suspension cradle. 2. Securely mount the lower
control arm in a vise.
Tools Assembled For Removal Of Front Bushing
3. Assemble for removal of the front bushing, the Bushing Receiver, Special Tool 6908-2, Bushing
Remover, Special Tool 6908-1, Nut, Special Tool
6908-3 thrust washer, threaded rod and small nut, as shown on the lower control arm and front
bushing.
4. To remove front bushing from lower control arm, hold the threaded rod stationary and tighten the
Nut, Special Tool 690-3. This will force the
front bushing out of the lower control arm and into Bushing Receiver, Special Tool 6908-2.
INSTALL
1. Securely mount the lower control arm in a vise.
Installation Position Of Lower Control Arm Front Bushing
NOTE: The lower control arm front bushing is a directional bushing. It must be installed in the lower
control arm positioned.
2. Position the front bushing in the lower control arm so that the 2 rubber blocks on the bushing are
positioned horizontally.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Service and Repair > Front > Page 5004
Tools Assembled For Installation Of Front Bushing
3. Assemble for installation of the front bushing, the Bushing Receiver, Special Tool 6908-5,
Bushing Installer, Special Tool 6908-4, Nut, Special
Tool 6908-3 thrust washer, threaded rod and small nut, on the lower control arm and front bushing.
4. To install the front bushing in lower control arm, hold the threaded rod stationary and tighten the
Nut, Special Tool 6908-3. This will pull the front
bushing into the lower control arm.
Correctly Installed Lower Control Arm Bushing
5. Continue pulling the bushing into the lower control arm until bushing is seated squarely against
the lower control arm and there is no gap between
the bushing and the lower control arm.
6. Install the lower control arm on the front suspension cradle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Service and Repair > Front > Page 5005
Control Arm Bushing: Service and Repair Rear
REMOVE
1. Remove the lower control arm from the front suspension cradle. 2. Mount the lower control arm
in a vise without using excessive clamping force.
Slit Lower Control Arm Rear Bushing
3. Using a sharp knife, (such as a razor) slit the bushing lengthwise to allow its removal from the
lower control arm. 4. Remove the bushing from the lower control arm.
INSTALL
CAUTION: Do not apply grease or any other type of lubricant other than the silicone lubricant
specified to the control arm bushing.
1. Apply Mopar Silicone Spray Lube or an equivalent, to the hole in lower control arm rear bushing.
This will aid in the installation of the bushing on
the lower control arm.
Correctly Installed Lower Control Arm Bushing
2. With the lower control arm held securely in a vise, install bushing on lower control arm. Install
bushing by pushing and rocking the bushing until it
is fully installed on lower control arm. Be sure when bushing is installed it is past the upset on the
end of the lower control arm.
3. The rear bushing of the lower control arm, when correctly installed, is to be positioned on the
lower control arm.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Specifications
Cross-Member: Specifications
To Body Attaching Bolts ......................................................................................................................
................................................ 163 Nm (120 ft. lbs.) Reinforcement Plate Attaching Bolts M-12
............................................................................................................................................ 108 Nm
(80 ft. lbs.) Reinforcement Plate Attaching Bolts M-14
.......................................................................................................................................... 166 Nm
(123 ft. lbs.) Cradle Plate To Cradle Attaching Bolts
............................................................................................................................................... 165 Nm
(123 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications
Front Steering Knuckle: Specifications
Ball Joint Stud Nut/Bolt ........................................................................................................................
............................................... 145 Nm (105 ft. lbs.) Wheel Stop ........................................................
....................................................................................................................................... 95 Nm (70 ft.
lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications > Page 5012
Front Steering Knuckle: Description and Operation
Front Steering Knuckle
The steering knuckle is a single casting with legs machined for attachment of the strut damper,
steering linkage, disc brake caliper, and lower control arm ball joint. The steering knuckle also has
the front hub and bearing mounted to it. The hub and bearing is positioned through the knuckle,
with the drive shaft constant velocity stub shaft splined through the center of the hub.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications > Page 5013
Front Steering Knuckle: Testing and Inspection
The front suspension knuckle is not a repairable component of the front suspension. It must be
replaced. If bent, broken, or damaged in any way, do not attempt to straighten or repair the steering
knuckle. Service replacement of the front hub/bearing assembly can be done with the front steering
knuckle remaining on the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal
Front Steering Knuckle: Service and Repair Removal
REMOVAL
1. Raise vehicle on jack stands or centered on a frame contact type hoist.
Hub And Bearing To Stub Axle Retaining Nut
2. Remove the cotter pin and nut lock from the end of the stub axle. 3. Remove the wheel and tire
assembly from the vehicle.
Wave Washer
4. Remove the wave washer from the end of the end of the stub axle.
CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the
ground or the weight of the vehicle is allowed to be supported by the tires.
5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to
hub nut.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 5016
Front Disc Brake Caliper Attaching Bolts
6. Remove the 2 front disc brake caliper to steering knuckle attaching bolts.
Brake Caliper Mounting To Steering Knuckle
7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle and then
removing bottom of caliper out from under machined abutment on steering knuckle.
Correctly Supported Disc Brake Caliper
8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut
assembly. Do not allow the brake caliper assembly to
hang by the brake flex hose.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 5017
Remove/Install Brake Rotor
9. Remove the brake rotor from the hub and bearing assembly.
Removing Tie Rod End Attaching Nut
10. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod
end using the following procedure, hold tie rod end
stud with a 11/32 socket while loosening and removing nut with a wrench.
Tie Rod End Removal From Steering Knuckle Arm
11. Remove tie rod end from steering knuckle using Remover, Special Tool MB-991113.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 5018
Front Wheel Speed Sensor
12. Remove the front wheel speed sensor from the steering knuckle.
Wheel Stop Location On Steering Knuckle
13. If equipped, remove the wheel stop from the steering knuckle. When installing the pinch bolt
when assembling the steering knuckle to the ball joint
, the pinch bolt must be installed from the rear facing the front on the vehicle.
Control Arm To Steering Knuckle Attachment
14. Remove the steering knuckle to ball joint stud, clamping nut and bolt from the steering knuckle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 5019
Separating Ball Joint Stud From Steering Knuckle
15. Using a pry bar, separate steering knuckle from ball joint stud. Note: Use caution when
separating ball joint stud from steering knuckle, so ball
joint seal does not get cut.
NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly
in steering knuckle, end of driveshaft must be supported.
Steering Knuckle Separation From Driveshaft
16. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft
assembly.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during removal. Remove nuts while holding bolts stationary in the steering knuckles.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 5020
Fig. 21 Strut To Steering Knuckle Mounting Bolt Removal
17. Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts. 18. Remove the
steering knuckle from the strut.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 5021
Front Steering Knuckle: Service and Repair Installation
INSTALLATION
1. Transfer, or install if necessary, a new hub/bearing assembly into the steering knuckle. Refer to
Hub And Bearing Assembly Service.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during installation. Install nuts while holding bolts stationary in the steering knuckles.
Correctly Installed Eccentric Attaching Bolt
CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts,
the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket.
2. Install steering knuckle back in clevis bracket of strut damper assembly. Install the strut damper
to steering knuckle attaching bolts. Tighten both
attaching bolts to a torque of 90 Nm (65 ft. lbs.) plus an additional 1/4 turn.
3. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the
stud of the ball joint assembly. 4. Install a new steering knuckle to ball joint stud, clamping bolt and
nut. Tighten the clamping bolt and nut to a torque of 145 Nm (105 ft. lbs.).
Torquing Tie Rod End Attaching Nut
5. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding
stud of tie rod end stationary using a 11/32
socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32
socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.).
6. Install braking disc on hub and bearing assembly. 7. Install disc brake caliper assembly on
steering knuckle. Caliper is installed by first sliding bottom of caliper under abutment on steering
knuckle,
and then rotating top of caliper against top abutment.
8. Install disc brake caliper assembly to steering knuckle attaching bolts. Tighten the disc brake
caliper assembly attaching bolts to a torque of 22 Nm
(195 inch. lbs.).
9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and
stub axle to hub/bearing assembly nut on stub axle
and securely tighten nut.
10. Install wheel speed sensor and mounting bolt on steering knuckle. Tighten the speed sensor
attaching bolt to a torque of 7 Nm (60 inch. lbs.). 11. Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the
required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm
(100 ft. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 5022
12. Lower vehicle.
Torquing Front Stub Axle To Hub Nut
13. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of
203 Nm (150 ft. lbs.) 14. Install the spring wave washer on the end of the stub axle. 15. Install the
hub nut lock, and a new cotter pin. Wrap cotter pin prongs tightly around the hub nut lock. 16. Set
front Toe on vehicle to required specification.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Description and Operation
Lateral Stabilizer Rod: Description and Operation
Rear Track Bar
On front wheel drive applications of this vehicle that are equipped with single leaf rear springs, a
track bar is used on the rear axle. The track bar connects the rear axle to the frame/body of the
vehicle. The track bar is isolated from the body of the vehicle by an isolator bushing located in each
end of the track bar. The track bar prevents excessive side-to-side movement of the rear axle. The
track bar is used to keep the location of the axle in the correct position for optimum handling and
control of the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Track Bar Mount
Lateral Stabilizer Rod: Service and Repair Track Bar Mount
REMOVE
1. Remove the track bar from the track bar mount.
Track Bar Mount
2. Remove the three bolts attaching the track bar mount to the body.
INSTALLATION
1. For installation, reverse removal procedure. Tighten bolts to 61 Nm (45 ft. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Track Bar Mount > Page 5028
Lateral Stabilizer Rod: Service and Repair Rear Track Bar Replacement
REMOVAL
Track Bar Mounting To Axle
1. Remove the nut and bolt mounting the track bar to the rear axle. 2. Remove the nut and bolt
attaching the track bar to the track bar mount on the body of the vehicle. Remove the track bar
from the track bar mount.
INSTALLATION
Track Bar Installation
Track Bar Bolt Installation
1. Install the track bar first into the body mount for the track bar. Install the track bar bolt with the
head of the bolt facing toward the rear of the
vehicle. Do not tighten.
2. Install the track bar into its mounting bracket on the rear axle. Install the track bar bolt with the
head of the bolt facing toward the rear of the
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair > Track Bar Mount > Page 5029
vehicle. Do not tighten.
3. Lower the vehicle to the ground until the full weight of the vehicle is supported by the wheels.
Tighten both track bar attaching bolts to a torque of
95 Nm (70 ft. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing >
Component Information > Specifications
Stabilizer Bushing: Specifications
FRONT:
Bushing Retainer Attaching Bolts
......................................................................................................................................................... 70
Nm (50 ft. lbs.)
REAR:
Bushing Retainer Attaching Bolts
......................................................................................................................................................... 61
Nm (45 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing >
Component Information > Specifications > Page 5034
Stabilizer Bushing: Service and Repair
If stabilizer bar to front suspension cradle bushings require replacement at time of inspection,
install new bushings before installing stabilizer bar back on the vehicle.
DISASSEMBLY
1. Stabilizer bar bushings are replaced by opening the slit on the bushings and peeling them off the
stabilizer bar.
ASSEMBLY
1. Install new bushings on stabilizer bar by spreading bushing at slit and forcing them onto
stabilizer bar.
Correctly Installed Stabilizer Bar To Cradle Bushing
NOTE: Bushings must be installed on stabilizer bar so the square corner of the bushing will be
down and slit in bushing will be facing the rear of the vehicle when the stabilizer is installed.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 02-004-01 > Jul > 01 > Front
Suspension - Knock/Squawk Sound
Stabilizer Link: Customer Interest Front Suspension - Knock/Squawk Sound
NUMBER: 02-004-01
GROUP: Suspension
DATE: July 6, 2001
SUBJECT: Knock/Squawk Sound From Front Suspension
OVERVIEW: This bulletin involves installing new front sway bar link assemblies.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Town & Country/Caravan/Voyager
2001 (RG) Chrysler Voyager (International Markets)
SYMPTOM/CONDITION:
1. A squawk/creak/groan sound is heard when turning the steering wheel at a stop or during a low
speed turn such as a parking lot maneuver.
2. A knocking/clunking sound is heard from the front suspension while driving over rough/bumpy
roads.
DIAGNOSIS:
1. With a helper in the vehicle, apply the parking brake, start the engine and turn the steering wheel
in both directions. Reach between the top of the front tire and the wheel well lip and grasp the sway
bar link. Listen or feel for the condition described above while the wheel is being turned. If the
condition is present, perform the Repair Procedure.
2. Drive the vehicle over rough/bumpy roads to verify condition. Raise the vehicle on an
appropriate hoist and perform a visual inspection of the front suspension. Repair or replace any
loose, damaged or worn components and test drive vehicle. It the condition is still present, perform
the Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Raise the vehicle on a frame contact hoist.
2. Remove both front wheels.
3. Remove the upper and lower sway bar link nuts and remove the sway bar link.
CAUTION:
WHEN INSTALLING THE NUTS TO THE STUDS OF THE SWAY BAR LINKS, DO NOT ALLOW
THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY INSERTING
A # 40 TORX BIT INTO THE END OF THE STUD.
4. Install the new sway bar link. Install the sway bar link nuts and torque to 88 N.m (65 ft. lbs.).
5. Perform steps 3 and 4 for the other sway bar link.
6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 N.m (50 ft. lbs.)
and then use a criss-cross pattern again to tighten to
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 02-004-01 > Jul > 01 > Front
Suspension - Knock/Squawk Sound > Page 5043
a final torque of 135 N.m (100 ft. lbs.).
7. Lower vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 02-03-00 > Feb > 00 > Front
Strut - Knock/Clunk Sound
Stabilizer Link: Customer Interest Front Strut - Knock/Clunk Sound
NUMBER: 02-03-00
GROUP: Front Suspension
DATE: Feb.25, 2000
MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager
(International Market)
SUBJECT: knock/Clunk Sound From Front Strut Area
OVERVIEW: This bulletin involves installing revised front sway bar link retaining nut/washer
assemblies.
SYMPTOM/CONDITION: A knocking/clunking sound coming from the front sway bar link is heard
inside and outside the vehicle when driving over rough roads.
DIAGNOSIS: Grasp and attempt to shake each front sway bar link. If either sway bar link feels
loose check the upper attachments at the strut to determine if either washer is missing. If both
upper washers are present, raise the vehicle to check the presence of both lower washers at the
sway bar attachment. If any of the four washers are missing, perform the following Repair
Procedure to replace all four nut & washer assemblies.
PARTS REQUIRED:
4 06505291AA Assembly, Nut/Washer
REPAIR PROCEDURE:
1. Raise the vehicle on a frame contact hoist. See Hoisting in the Lubrication and Maintenance
section of the appropriate service manual if you are unfamiliar with the procedure.
2. Remove both front wheels.
CAUTION:
WHEN REMOVING THE NUTS FROM THE STUDS OF THE STABILIZER LINKS, DO NOT
ALLOW THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY
INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD. USE OF A NON-PLUS IP BIT
MAY RESULT IN ROUNDING OUT THE END OF THE STUD.
3. Remove each stabilizer link retaining nut/washer while holding the stabilizer link stud with a Torx
Plus 40 IP bit, do not allow the stud to rotate in its socket.
4. Install revised nut/washer, p/n 06505291AA and tighten to 88 Nm (65 ft. lbs.).
5. Repeat steps 3 and 4 for the other three nut/washers.
6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 Nm (50 ft. lbs.)
and then use a criss-cross pattern again to tighten to a final torque of 135 Nm (100 ft. lbs.)
7. Lower the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
02-20-10-96 0.7 Hrs.
FAILURE CODE: P8- New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 02-004-01 > Jul
> 01 > Front Suspension - Knock/Squawk Sound
Stabilizer Link: All Technical Service Bulletins Front Suspension - Knock/Squawk Sound
NUMBER: 02-004-01
GROUP: Suspension
DATE: July 6, 2001
SUBJECT: Knock/Squawk Sound From Front Suspension
OVERVIEW: This bulletin involves installing new front sway bar link assemblies.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Town & Country/Caravan/Voyager
2001 (RG) Chrysler Voyager (International Markets)
SYMPTOM/CONDITION:
1. A squawk/creak/groan sound is heard when turning the steering wheel at a stop or during a low
speed turn such as a parking lot maneuver.
2. A knocking/clunking sound is heard from the front suspension while driving over rough/bumpy
roads.
DIAGNOSIS:
1. With a helper in the vehicle, apply the parking brake, start the engine and turn the steering wheel
in both directions. Reach between the top of the front tire and the wheel well lip and grasp the sway
bar link. Listen or feel for the condition described above while the wheel is being turned. If the
condition is present, perform the Repair Procedure.
2. Drive the vehicle over rough/bumpy roads to verify condition. Raise the vehicle on an
appropriate hoist and perform a visual inspection of the front suspension. Repair or replace any
loose, damaged or worn components and test drive vehicle. It the condition is still present, perform
the Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Raise the vehicle on a frame contact hoist.
2. Remove both front wheels.
3. Remove the upper and lower sway bar link nuts and remove the sway bar link.
CAUTION:
WHEN INSTALLING THE NUTS TO THE STUDS OF THE SWAY BAR LINKS, DO NOT ALLOW
THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY INSERTING
A # 40 TORX BIT INTO THE END OF THE STUD.
4. Install the new sway bar link. Install the sway bar link nuts and torque to 88 N.m (65 ft. lbs.).
5. Perform steps 3 and 4 for the other sway bar link.
6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 N.m (50 ft. lbs.)
and then use a criss-cross pattern again to tighten to
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 02-004-01 > Jul
> 01 > Front Suspension - Knock/Squawk Sound > Page 5053
a final torque of 135 N.m (100 ft. lbs.).
7. Lower vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 02-03-00 > Feb
> 00 > Front Strut - Knock/Clunk Sound
Stabilizer Link: All Technical Service Bulletins Front Strut - Knock/Clunk Sound
NUMBER: 02-03-00
GROUP: Front Suspension
DATE: Feb.25, 2000
MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager
(International Market)
SUBJECT: knock/Clunk Sound From Front Strut Area
OVERVIEW: This bulletin involves installing revised front sway bar link retaining nut/washer
assemblies.
SYMPTOM/CONDITION: A knocking/clunking sound coming from the front sway bar link is heard
inside and outside the vehicle when driving over rough roads.
DIAGNOSIS: Grasp and attempt to shake each front sway bar link. If either sway bar link feels
loose check the upper attachments at the strut to determine if either washer is missing. If both
upper washers are present, raise the vehicle to check the presence of both lower washers at the
sway bar attachment. If any of the four washers are missing, perform the following Repair
Procedure to replace all four nut & washer assemblies.
PARTS REQUIRED:
4 06505291AA Assembly, Nut/Washer
REPAIR PROCEDURE:
1. Raise the vehicle on a frame contact hoist. See Hoisting in the Lubrication and Maintenance
section of the appropriate service manual if you are unfamiliar with the procedure.
2. Remove both front wheels.
CAUTION:
WHEN REMOVING THE NUTS FROM THE STUDS OF THE STABILIZER LINKS, DO NOT
ALLOW THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY
INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD. USE OF A NON-PLUS IP BIT
MAY RESULT IN ROUNDING OUT THE END OF THE STUD.
3. Remove each stabilizer link retaining nut/washer while holding the stabilizer link stud with a Torx
Plus 40 IP bit, do not allow the stud to rotate in its socket.
4. Install revised nut/washer, p/n 06505291AA and tighten to 88 Nm (65 ft. lbs.).
5. Repeat steps 3 and 4 for the other three nut/washers.
6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 Nm (50 ft. lbs.)
and then use a criss-cross pattern again to tighten to a final torque of 135 Nm (100 ft. lbs.)
7. Lower the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
02-20-10-96 0.7 Hrs.
FAILURE CODE: P8- New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > Page 5058
Stabilizer Link: Specifications
FRONT:
Attaching Nuts .....................................................................................................................................
................................................. 88 Nm (65 ft. lbs.)
REAR:
Attaching Nuts .....................................................................................................................................
................................................. 61 Nm (45 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut
Tower Corrosion
Strut / Shock Tower: Customer Interest Suspension/Body - Strut Tower Corrosion
NUMBER: 23-044-02
GROUP: Body
DATE: Oct. 14, 2002
SUBJECT: NS Strut Tower Corrosion
OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan
SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between
the strut and upper load path beam inner panel (inner fender).
DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of
the following repair procedures.
NOTE:
ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD
BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED
EQUIPMENT REQUIRED
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or
primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE:
REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE
PARTS KITS.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut
Tower Corrosion > Page 5067
TIME ALLOWANCE
FAILURE CODE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 >
Suspension/Body - Strut Tower Corrosion
Strut / Shock Tower: All Technical Service Bulletins Suspension/Body - Strut Tower Corrosion
NUMBER: 23-044-02
GROUP: Body
DATE: Oct. 14, 2002
SUBJECT: NS Strut Tower Corrosion
OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan
SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between
the strut and upper load path beam inner panel (inner fender).
DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of
the following repair procedures.
NOTE:
ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD
BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED
EQUIPMENT REQUIRED
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or
primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE:
REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE
PARTS KITS.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 >
Suspension/Body - Strut Tower Corrosion > Page 5073
TIME ALLOWANCE
FAILURE CODE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates
Suspension Spring ( Coil / Leaf ): Technical Service Bulletins Electrical/Suspension - Service
Manual Updates
NUMBER: 26-03-99
GROUP: Miscellaneous
DATE: March, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revisions to the Coil Spring Installation Procedures
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5078
2-29
Revisions to the Wiring Schematics
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5079
8W-10-2A
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5080
8W-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5081
8W-10-16
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5082
8W-12-13
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5083
8W-20-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5084
8W-30-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5085
8W-30-5
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5086
8W-30-17
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5087
8W-30-18
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5088
8W-30-19
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5089
8W-30-21
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5090
8W-30-22
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5091
8W-33-3
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5092
8W-42-3
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5093
8W-62-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5094
8W-62-4
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5095
8W-62-5
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5096
8W-70-5
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5097
8W-80-28
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5098
8W-80-57
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5099
8W-80-70
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5100
8W-80-71
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5101
Engine Compartment Connections - Late Build
8W-90-10A
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5102
8W-90-10
Revisions to the automatic transmission fluid and filter service procedures
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5103
21-1
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5104
21-16
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5105
21-17
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5106
Suspension Spring ( Coil / Leaf ): Technical Service Bulletins Suspension - Coil Spring Service
Procedures Update
NUMBER: 26-03-00E
GROUP: Miscellaneous
DATE: March, 2000
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Grand Voyager, Town & Country Service Manual - Publication Number 81-370-9105
DESCRIPTION OF CHANGES
Updates to the coil spring service procedures
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Electrical/Suspension - Service Manual Updates > Page 5107
2-28
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Technical Service Bulletins > Page 5108
Suspension Spring ( Coil / Leaf ): Specifications
Spring Plate To Axle Attaching Bolts
.................................................................................................................................................... 101
Nm (75 ft. lbs.) Rear Mount To Body Bolts ..........................................................................................
............................................................................ 61 Nm (45 ft. lbs.) Front Mount To Body Bolts .......
..............................................................................................................................................................
61 Nm (45 ft. lbs.) To Front Hanger Mounting Nut
............................................................................................................................................................
156 Nm (115 ft. lbs.) Shackle Plate Nuts .............................................................................................
....................................................................................... 61 Nm (45 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Replacement
Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Replacement
Removal
REMOVAL
1. Raise vehicle on frame contact hoist to a comfortable working position. 2. Support axle with a
jack stand. Pad should just contact axle.
Rear Shock Mounting Bolt
3. Begin removal of the shock absorber lower mounting bolt.
NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack.
If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or
by pulling on axle).
4. Using 2 jack stands positioned under the outer ends of the axle, raise the axle enough to remove
the weight of the axle from the rear springs.
Axle Plate Bolts
5. Loosen and remove the axle plate bolts from the rear axle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Replacement > Page 5111
Axle Plate
6. Remove the axle plate from the rear axle and the leaf spring. 7. Using the jack stands slowly
lower the rear axle, permitting the rear springs to hang free.
Leaf Spring Front Mount
8. Loosen and remove the 4 bolts from the front mount of the leaf spring.
Rear Spring Hanger
9. Loosen and remove the nuts from the spring hanger for the rear leaf spring. Then remove the
hanger plate from the hanger and remove the spring
from the spring hanger.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Replacement > Page 5112
10. Remove the leaf spring from the vehicle.
11. Loosen and remove the pivot bolt from the front mount of the rear leaf spring.
FRONT BUSHING REPLACEMENT
1. Install leaf spring in a proper holding fixture. 2. Install leaf spring press Special Tool C-4212-F. 3.
Install adapter Special Tool C-4212-3. 4. Tighten leaf spring press until bushing is extracted from
leaf spring. 5. Remove leaf spring press from leaf spring. 6. Insert replacement bushing into the
leaf spring eye. Verify that the bushing flange is on the left side of the leaf spring when leaf spring
is in the in
vehicle installed position.
7. Install leaf spring press Special Tool C-4212-F. 8. Install adapter Special Tool C-4212-4. 9.
Tighten leaf spring press until bushing flange bottoms solidly against leaf spring eye.
10. Remove leaf spring press and adapter. 11. Bend the bushing tabs so that they are contacting
the leaf spring.
Installation
INSTALLATION
1. Assemble front spring mount to front of spring eye and install pivot bolt and nut. Do not tighten.
CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring.
2. Raise front of spring and install four hanger bolts, tighten to 61 Nm (45 ft. lbs.) torque. 3. Install
rear of spring onto rear spring shackle. Install shackle plate. Do not tighten. 4. Verify lower leaf
spring isolator is in position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Replacement > Page 5113
5. Raise axle into correct position on leaf spring with axle centered under spring locator post. 6.
Verify that the leaf spring isolator is correctly positioned in the axle plate. 7. Install axle plate on the
spring. 8. Install axle plate bolts. Tighten bolts to 101 Nm (75 ft. lbs.) torque. 9. Install shock
absorber bolts. Do not tighten.
10. Lower vehicle to floor so that the full curb weight of vehicle is supported by the tires. 11.
Tighten component fasteners as follows:
- Front pivot bolt 156 Nm (115 ft. lbs.)
- Shackle nuts 61 Nm (45 ft. lbs.)
- Shock absorber bolts 101 Nm (75 ft. lbs.)
12. If the vehicle is not equipped with antilock brakes, raise vehicle and the connect the actuator for
the height sensing proportioning valve on the rear
leaf spring. Adjust the height sensing proportioning valve.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Replacement > Page 5114
Suspension Spring ( Coil / Leaf ): Service and Repair Mount Replacement
Front
REMOVAL
Leaf Spring Front Mount
1. Loosen the pivot bolt attaching the front of the leaf spring to the spring mount. 2. Install a
jackstand under the side of the axle having the leaf spring mount removed. Using the jackstand
support the weight of the axle and leaf
spring.
3. Remove the lower mounting bolt from the shock absorber. 4. Remove the bolts attaching the leaf
spring front mount to the body of the vehicle. 5. Lower the leaf spring and remove the front mount
from the spring.
INSTALLATION
1. For installation, reverse removal procedure. Do not tighten front pivot bolt fully until vehicle is
lowered and the full vehicle weight is applied to
the rear wheels. Tighten leaf spring front mount bolts to 61 Nm (45 ft. lbs.). Tighten leaf spring front
pivot bolt to 156 Nm (115 ft. lbs.).
Rear
REMOVE
Leaf Spring Shackle Nuts (FWD)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Replacement > Page 5115
Rear Spring Hanger
1. Remove the attaching nuts and bolts from the leaf spring rear shackle. 2. Install a jackstand
under the side of the axle having the leaf spring mount removed. Using the jackstand, support the
weight of the axle and leaf
spring.
3. Remove the lower mounting bolt from the shock absorber.
Rear Spring Mount
4. Remove the bolts attaching the leaf spring rear mount to the body of the vehicle. 5. Lower the
jackstand and the rear of the leaf spring. Remove the shackle from the leaf spring bushing.
INSTALL
CAUTION: The following sequence must be followed when tightening the pin nuts on the rear
hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque.
Then tighten the retaining bolts for the inner to outer half of the spring hanger to the specified
torque. This sequence must be followed to avoid bending the spring hanger.
1. For installation, reverse removal procedure. Do not tighten rear spring shackle nuts fully until
vehicle is lowered and the full vehicle weight is
applied to the rear wheels. Tighten rear spring mount bolts to 61 Nm (45 ft. lbs.). Tighten shackle
nuts to 61 Nm (45 ft. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep >
98 > Front Strut Bearings - Squeaking/Chirping Noise
Technical Service Bulletin # 02-10-98 Date: 980925
Front Strut Bearings - Squeaking/Chirping Noise
NO: 02-10-98
GROUP: Suspension
DATE: Sept. 25, 1998
SUBJECT: Squeaking Noise From Strut Bearing(s)
MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT THROUGH OCT. 1, 1998.
SYMPTOM/CONDITION:
A squeaking/chirping noise is heard (inside or outside the vehicle) from the strut tower area(s)
when turning the steering wheel or when the vehicle is driven over any irregularities in the road
surface.
DIAGNOSIS:
With the vehicle on a level surface, hold a front suspension coil spring, with your hands near 180°
apart, and try to rotate the spring right and left. If a squeaking/chirping noise is heard from the top
of the strut tower, perform the Repair Procedure. Repeat for the opposite side strut tower.
Parts Information:
AR (2) 04684418 Bearing, Strut Upper Pivot
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
02-05-39-93 One Side 0.9 Hrs.
02-05-39-94 Two Sides 1.6 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves replacing the strut upper pivot bearing(s).
WARNING:
DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS
INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED.
1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the
Lubrication and Maintenance section of the service manual, for the required lifting procedure to be
used for this vehicle.
2. Remove the front wheel and tire assembly from the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep >
98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5124
3. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket
from the strut damper brackets (Figure 1).
NOTE:
WHEN REMOVING NUT FROM STUD OF STABILIZER BAR ATTACHING LINK, DO NOT
ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40
IP BIT IN THE END OF THE STUD AS SHOWN IN FIGURE 2.
4. Remove the stabilizer bar attaching link from the bracket on the strut assembly (Figure 2).
CAUTION:
THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND
MUST NOT BE TURNED DURING REMOVAL. REMOVE NUTS WHILE HOLDING BOLTS
STATIONARY IN THE STEERING KNUCKLES.
5. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts (Figure 3).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep >
98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5125
6. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the
strut assembly from the vehicle (Figure 4).
7. Position the strut assembly in the strut coil spring compressor (Pentastar Service Equipment
(PSE) tool W-7200, or the equivalent) closely following the manufacturers instructions. The strut
clevis bracket should be positioned outward. Position the upper hooks on top of the coil spring
upper seat. Place a clamp on the lower end of the coil spring, so the strut is held in place once the
strut shaft nut is removed (Figure 5 and 6).
WARNING:
DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED.
THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING
SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT
NUT IS REMOVED.
8. Compress the coil spring until all coil spring tension is removed from the upper mount.
9. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm
socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove
the nut from the strut shaft.
10. Remove the upper mount from the strut shaft.
11. Remove the upper pivot bearing from the top of the coil spring upper seat by pulling it straight
up.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep >
98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5126
12. Install the new pivot bearing on the top of the upper spring seat. The bearing must be installed
on upper seat with the smaller diameter side of the pivot bearing toward the spring seat (Figure 7).
Be sure the pivot bearing is sitting flat on the spring seat once mounted.
13. Install the upper mount over the strut shaft and onto the top of the pivot bearing and upper seat
(Figure 6). Loosely install the retaining nut on the strut shaft.
14. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft
retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding
the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 94 Nm (70 ft. lbs.).
15. Slowly release the tension from the coil spring by backing off the spring compressor drive fully.
As the tension is relieved, make sure the upper mount, pivot bearing and upper seat align properly.
Remove the clamp from the lower end of the coil spring and strut. Push back the spring
compressor upper and lower hooks, then remove the strut assembly from the spring compressor.
16. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut
mount into the holes in strut tower. Install the 3 upper strut mount attaching nut/washer assemblies.
Then using a crow foot, tighten the 3 attaching nuts to a torque of 28 Nm (250 in. lbs.).
CAUTION:
THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND
MUST NOT BE TURNED DURING INSTALLATION. INSTALL NUTS WHILE HOLDING BOLTS
STATIONARY IN THE STEERING KNUCKLES.
17. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly
clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle
mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts (Figure 3).
NOTE:
IF STRUT ASSEMBLY IS ATTACHED TO STEERING KNUCKLE USING A CAM BOLT, THE
CAM BOLT MUST BE INSTALLED IN THE LOWER SLOTTED HOLE ON THE STRUT CLEVIS
BRACKET. ALSO, ATTACHING BOLTS SHOULD BE INSTALLED WITH THE NUTS FACING
THE FRONT OF THE VEHICLE.
18. Tighten the strut assembly to steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.)
plus an additional 1/4 turn after specified torque is met.
19. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching
link to strut bracket attaching nut.
NOTE:
WHEN TORQUING NUT ON STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW
STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN
THE END OF THE STUD (FIGURE 8).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep >
98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5127
20. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40 IP bit and crowfoot to a
torque of 88 Nm (65 ft. lbs.) (Figure 8).
21. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly
brackets (Figure 1). Tighten the routing bracket attaching bolts to a torque of 13 Nm (100 ft. lbs.).
22. Install the wheel/tire assembly on the vehicle.
23. Install and tighten the wheel mounting stud nuts in a cris-cross pattern until all nuts are torqued
to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm
(100 ft. lbs.).
24. Repeat step 2 through 23 for the other side strut, if necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise
Technical Service Bulletin # 02-10-98 Date: 980925
Front Strut Bearings - Squeaking/Chirping Noise
NO: 02-10-98
GROUP: Suspension
DATE: Sept. 25, 1998
SUBJECT: Squeaking Noise From Strut Bearing(s)
MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT THROUGH OCT. 1, 1998.
SYMPTOM/CONDITION:
A squeaking/chirping noise is heard (inside or outside the vehicle) from the strut tower area(s)
when turning the steering wheel or when the vehicle is driven over any irregularities in the road
surface.
DIAGNOSIS:
With the vehicle on a level surface, hold a front suspension coil spring, with your hands near 180°
apart, and try to rotate the spring right and left. If a squeaking/chirping noise is heard from the top
of the strut tower, perform the Repair Procedure. Repeat for the opposite side strut tower.
Parts Information:
AR (2) 04684418 Bearing, Strut Upper Pivot
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
02-05-39-93 One Side 0.9 Hrs.
02-05-39-94 Two Sides 1.6 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves replacing the strut upper pivot bearing(s).
WARNING:
DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS
INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED.
1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the
Lubrication and Maintenance section of the service manual, for the required lifting procedure to be
used for this vehicle.
2. Remove the front wheel and tire assembly from the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5133
3. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket
from the strut damper brackets (Figure 1).
NOTE:
WHEN REMOVING NUT FROM STUD OF STABILIZER BAR ATTACHING LINK, DO NOT
ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40
IP BIT IN THE END OF THE STUD AS SHOWN IN FIGURE 2.
4. Remove the stabilizer bar attaching link from the bracket on the strut assembly (Figure 2).
CAUTION:
THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND
MUST NOT BE TURNED DURING REMOVAL. REMOVE NUTS WHILE HOLDING BOLTS
STATIONARY IN THE STEERING KNUCKLES.
5. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts (Figure 3).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5134
6. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the
strut assembly from the vehicle (Figure 4).
7. Position the strut assembly in the strut coil spring compressor (Pentastar Service Equipment
(PSE) tool W-7200, or the equivalent) closely following the manufacturers instructions. The strut
clevis bracket should be positioned outward. Position the upper hooks on top of the coil spring
upper seat. Place a clamp on the lower end of the coil spring, so the strut is held in place once the
strut shaft nut is removed (Figure 5 and 6).
WARNING:
DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED.
THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING
SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT
NUT IS REMOVED.
8. Compress the coil spring until all coil spring tension is removed from the upper mount.
9. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm
socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove
the nut from the strut shaft.
10. Remove the upper mount from the strut shaft.
11. Remove the upper pivot bearing from the top of the coil spring upper seat by pulling it straight
up.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5135
12. Install the new pivot bearing on the top of the upper spring seat. The bearing must be installed
on upper seat with the smaller diameter side of the pivot bearing toward the spring seat (Figure 7).
Be sure the pivot bearing is sitting flat on the spring seat once mounted.
13. Install the upper mount over the strut shaft and onto the top of the pivot bearing and upper seat
(Figure 6). Loosely install the retaining nut on the strut shaft.
14. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft
retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding
the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 94 Nm (70 ft. lbs.).
15. Slowly release the tension from the coil spring by backing off the spring compressor drive fully.
As the tension is relieved, make sure the upper mount, pivot bearing and upper seat align properly.
Remove the clamp from the lower end of the coil spring and strut. Push back the spring
compressor upper and lower hooks, then remove the strut assembly from the spring compressor.
16. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut
mount into the holes in strut tower. Install the 3 upper strut mount attaching nut/washer assemblies.
Then using a crow foot, tighten the 3 attaching nuts to a torque of 28 Nm (250 in. lbs.).
CAUTION:
THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND
MUST NOT BE TURNED DURING INSTALLATION. INSTALL NUTS WHILE HOLDING BOLTS
STATIONARY IN THE STEERING KNUCKLES.
17. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly
clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle
mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts (Figure 3).
NOTE:
IF STRUT ASSEMBLY IS ATTACHED TO STEERING KNUCKLE USING A CAM BOLT, THE
CAM BOLT MUST BE INSTALLED IN THE LOWER SLOTTED HOLE ON THE STRUT CLEVIS
BRACKET. ALSO, ATTACHING BOLTS SHOULD BE INSTALLED WITH THE NUTS FACING
THE FRONT OF THE VEHICLE.
18. Tighten the strut assembly to steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.)
plus an additional 1/4 turn after specified torque is met.
19. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching
link to strut bracket attaching nut.
NOTE:
WHEN TORQUING NUT ON STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW
STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN
THE END OF THE STUD (FIGURE 8).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 5136
20. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40 IP bit and crowfoot to a
torque of 88 Nm (65 ft. lbs.) (Figure 8).
21. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly
brackets (Figure 1). Tighten the routing bracket attaching bolts to a torque of 13 Nm (100 ft. lbs.).
22. Install the wheel/tire assembly on the vehicle.
23. Install and tighten the wheel mounting stud nuts in a cris-cross pattern until all nuts are torqued
to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm
(100 ft. lbs.).
24. Repeat step 2 through 23 for the other side strut, if necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Specifications > Shock Absorber
Suspension Strut / Shock Absorber: Specifications Shock Absorber
Mounting Bolts (All) .............................................................................................................................
................................................. 101 Nm (75 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Specifications > Shock Absorber > Page 5139
Suspension Strut / Shock Absorber: Specifications Struts
Tower Attaching Nuts ..........................................................................................................................
............................................... 28 Nm (250 inch lbs.) Clevis Bracket To Steering Knuckle
.................................................................................................................................. 88 Nm (65 ft.
lbs.) Plus 1/4 Turn Shaft Nut ...............................................................................................................
.................................................................................. 100 Nm (75 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Description and Operation > Front
Suspension Strut / Shock Absorber: Description and Operation Front
A MacPherson type strut assembly is used in place of the front suspension upper control arm and
upper ball joint. The bottom of the strut mounts directly to the steering knuckle using 2 attaching
bolts and nuts going through the strut clevis bracket and steering knuckle. The top of the strut
mounts directly to the strut tower of the vehicle using the threaded studs on the strut assemblies
upper mount. During steering maneuvers, the strut assembly (through a pivot bearing in the upper
strut mount) and steering knuckle (through the lower ball joint) turn as an assembly. The strut
assembly is used to dampen the front suspension and smooth ride of the vehicle. The strut
assembly includes the following components: A rubber isolated upper mount, a pivot bearing, an
upper spring seat, a jounce bumper, a dust shield, a coil spring, a lower isolator, and a strut
(dampener). Each component is serviced by removing the strut assembly from the vehicle and
disassembling it.
COIL SPRING
The strut and front suspension of the vehicle is supported by coil springs positioned around the
upper half of each strut. The springs are contained between the upper and the lower seats of the
strut assembly. Coil springs are rated separately for each corner or side of the vehicle depending
on optional equipment and type of vehicle service. During service procedures of the strut assembly,
if both springs are removed, mark the springs to ensure installation in original position. Each coil
spring comes with a plastic sleeve on the second coil of the spring. This plastic sleeve is a noise
insulator for the coil spring.
NOTE: If a coil spring requires replacement, be sure that it is replaced with a spring meeting the
correct load rating for the vehicle and its specific options.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Description and Operation > Front > Page 5142
Suspension Strut / Shock Absorber: Description and Operation Shock Absorber
REAR LOAD LEVELING
A load-leveling shock is available. The self leveling shock absorbers are a self-contained vehicle
leveling system and shock absorber combined. It does not require an external compressor, hoses,
height leveling sensors, etc. It uses road inputs (bumps, stops, starts, turns, acceleration,
deceleration, etc.) to activate pumping, which is just the extension and compression of the shock
absorber. On the outside, it looks like a larger than normal shock absorber. Internally, it consists of
a hydraulic pump and gas-spring cushion for leveling, as well as the normal shock absorbing
mechanism. All the height leveling sensors, pump, etc., are contained inside the shocks. These
load-leveling shock absorbers mount the same, but use longer fasteners than the standard shock
absorbers. Although the fasteners are longer, the torque specifications are the same.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Description and Operation > Page 5143
Suspension Strut / Shock Absorber: Testing and Inspection
Strut Assembly Inspection
1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged strut assembly dust
boots. 3. Inspect the coil spring isolator on the lower spring seat, for any signs of damage or
deterioration.
Strut Assembly Leakage Inspection
4. Lift dust boot and inspect strut assembly for evidence of fluid running from the upper end of fluid
reservoir. (Actual leakage will be a stream of
fluid running down the side and dripping off lower end of unit). A slight amount of seepage between
the strut rod and strut shaft seal is not unusual and does not affect performance of the strut
assembly. Also inspect jounce bumpers for signs of damage or deterioration.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Replacement
Suspension Strut / Shock Absorber: Service and Repair Replacement
Removal
REMOVAL
WARNING: DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY
IS INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED.
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the wheel
and tire assembly from location on front of vehicle requiring strut removal. 3. If both strut
assemblies are to be removed, mark the strut assemblies right or left according to which side of the
vehicle they were removed from.
Brake Hose And Speed Sensor Cable Routing
4. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket
from the strut damper brackets.
Stabilizer Bar Link To Strut Attachment
NOTE: When removing nut from stud of stabilizer bar attaching link, do not allow stud to rotate.
Hold stud from rotating by inserting a Torx Plus 401P bit in the end of the stud.
5. Remove the stabilizer bar attaching link from the bracket on the strut assembly.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during removal. Remove nuts while holding bolts stationary in the steering knuckles.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Replacement > Page 5146
Strut Damper Attachment To Steering Knuckle
6. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts.
Strut Assembly To Strut Tower Attaching Nuts
7. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the
strut assembly from the vehicle. 8. To disassemble and reassemble the strut assembly, refer to
Overhaul.
Installation
INSTALLATION
1. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount
into the holes in shock tower. Install the 3 upper
strut mount attaching nut/washer assemblies. Then using a crow foot tighten the 3 attaching nuts to
a torque of 28 Nm (250 inch. lbs.).
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during installation. Install nuts while holding bolts stationary in the steering knuckles.
2. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly
clevis bracket. Align the strut assembly clevis
bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to
steering knuckle attaching bolts. If strut assembly is attached to steering knuckle using a cam bolt,
the cam bolt must be installed in the lower slotted hole on strut clevis bracket. Also, attaching bolts
should be installed with the nuts facing the front of the vehicle. Tighten the strut assembly to
steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.) plus an additional 1/4 turn after
specified torque is met.
3. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching link
to strut bracket attaching nut.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Replacement > Page 5147
Torquing Stabilizer Bar Link To Strut Attaching Nut
NOTE: When torquing nut on stud of stabilizer bar attaching link, do not allow stud to rotate. Hold
stud from rotating by inserting a Torx Plus 401P bit in the end of the stud.
4. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40IP bit and crowfoot as
shown to a torque of 88 Nm (65 ft. lbs.) 5. Install hydraulic brake hose and speed sensor cable
routing brackets on the strut assembly brackets. Tighten the routing bracket attaching bolts to a
torque of 13 Nm (10 ft. lbs.).
6. Install the wheel/tire assembly on the vehicle. 7. Install and tighten the wheel mounting stud nuts
in proper sequence until all nuts are torqued to half specification. Then repeat the tightening
sequence to the full specified torque of 135 Nm (100 ft. lbs.).
Rear
REMOVAL
1. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type
hoist. 2. Support the rear axle of the vehicle using 2 jackstands positioned at the outer ends of the
axle.
NOTE: If the shock absorber lower mounting bolt deflects upward during removal, raise axle by
adjusting the support jack. If the lower shock absorber bolt deflects downward during removal,
lower the axle by adjusting the support jack.
3. Remove the shock absorber lower mounting bolt. 4. While holding shock absorber, remove the
shock absorber upper mounting bolt and shock absorber.
INSTALLATION
1. While holding shock absorber in position against the frame rail, install the shock absorber upper
mounting bolt. 2. Install the shock absorber lower mounting bolt securing the lower end of the
shock absorber to the axle. 3. Remove the support jack. 4. Lower the vehicle to the ground so the
full curb weight of the vehicle is supported by the suspension. 5. Tighten the upper and lower shock
absorber mounting bolt to a torque of 101 Nm (75 ft. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Replacement > Page 5148
Suspension Strut / Shock Absorber: Service and Repair Overhaul
Disassembly
The strut assembly must be removed from the vehicle for it to be disassembled and assembled.
For the disassembly and assembly of the strut assembly, use strut spring compressor, Pentastar
Service Equipment (PSE) tool W-7200, or the equivalent, to compress the coil spring. Follow the
tool manufacturer's instructions closely.
DISASSEMBLY
1. If both struts are being serviced at the same time, mark the coil spring and strut assembly
according to which side of the vehicle the strut was
removed from, and which strut the coil spring was removed from.
Strut Assembly In Compressor
Upper Hooks Positioned
2. Position the strut assembly in the strut coil spring compressor following the manufacturers
instructions. The strut clevis bracket should be
positioned outward. Position the upper hooks on top of the coil spring upper seat. Place a clamp on
the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed.
WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS
COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE
COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT
BEARING, BEFORE THE SHAFT NUT IS REMOVED.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Replacement > Page 5149
3. Compress the coil spring until all coil spring tension is removed from the upper mount.
Retaining Nut Removal/Installation
4. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm
socket on the hex on the end of the strut shaft.
While holding the strut shaft from turning, remove the nut from the strut shaft.
5. Remove the upper mount from the strut shaft. 6. If the upper pivot bearing needs to be serviced,
remove it from the top of the coil spring upper seat by pulling it straight up. 7. Remove the clamp
from the bottom of the coil spring and remove the strut out through the bottom of the coil spring.
NOTE: If the coil spring or upper mount need to be serviced, proceed with the next step, otherwise,
proceed with step 10.
8. Release the tension from the coil spring by backing off the compressor drive fully. Push back the
compressor upper hooks and remove the upper
spring seat.
9. Remove the coil spring from the spring compresser.
Dust Shield/Jounce Bumper
10. Remove the dust shield and jounce bumper as an assembly from the strut shaft by pulling both
straight up and off the strut shaft. The dust shield
cannot be separated from the jounce bumper until after it is removed from strut shaft.
11. Remove the jounce bumper from the dust shield. The jounce bumper is removed from the dust
shield by collapsing the dust shield until the jounce
bumper can be pulled free from the dust boot.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Replacement > Page 5150
Strut Lower Spring Seat Isolator
12. Remove the spring isolator from the lower spring seat on the strut. 13. Inspect the strut
assembly components for the following and replace as necessary:
- Inspect the strut for any condition of shaft binding over the full stroke of the shaft.
- Check the upper mount for cracks and distortion and its retaining studs for any sign of damage.
- Check the upper seat for severe deterioration of the rubber isolator.
- Check for binding of the strut assembly pivot bearing.
- Inspect the dust shield for rips and deterioration.
- Inspect the jounce bumper for cracks and signs of deterioration.
Assembly
The content of this article reflects the changes called out by TSBs 26-03-99 and 26-03-00.
ASSEMBLY
NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step,
otherwise, proceed with step 5.
Coil Spring Positioned (Right Spring Shown)
1. Place the coil spring in the compressor following the manufacturers instructions. Proper
orientation of the spring to the strut (once installed) is
necessary. Consider the following when placing the coil spring in the compressor: From above, the
compressor back is at the 12 o'clock position and you, standing in the front of the machine, are at
the 6 o'clock position. For left side springs, place the lower coil spring end at the 7 o'clock position.
For right side springs, place the lower coil spring end at the 5 o'clock position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Replacement > Page 5151
Upper Seat Notch Position
2. Install the upper seat on top of the coil spring. Position the notch in the perimeter of the upper
seat toward the front of the compressor.
3. Position the upper hooks on top of the coil spring upper seat so the upper hooks span the outer
shoulder of the upper seat. 4. Compress the coil spring.
Pivot Bearing Installation
5. If the pivot bearing has been removed form the upper seat, install the pivot bearing on the top of
the upper spring seat. The bearing must be
installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat.
Be sure the pivot bearing is sitting flat on the spring seat once mounted.
6. Install the spring isolator on the lower spring seat of the strut. When installing the spring isolator,
be sure the 2 retaining tabs on the spring isolator
are installed in the 2 holes in the spring seat. When installed, the oversize holes in the spring seat
should line up with the holes in the spring isolator.
Jounce Bumper On Strut Shaft
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Replacement > Page 5152
7. Install the jounce bumper on the strut shaft. The jounce bumper is to be installed with the small
end pointing downward.
Installing Dust Shield
8. Install the dust shield on the strut. Collapse and stretch the dust shield down over the top of the
jounce bumper until the dust shield snaps into the
slot on the jounce bumper. Return the dust shield to its fully extended length.
Strut Assembly In Compressor
9. Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower
end of the coil spring. The clevis bracket on the
strut should point straight outward away from the compressor (to the 6 o'clock position). Install the
clamp on the lower end of the coil spring and strut, so the strut is held in place.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Replacement > Page 5153
Top View Lower Spring Seats
Proper orientation of the coil spring to the strut is necessary. Verify the lower end of the coil spring
is contacting the strut's lower spring seat at the proper location using the image as a guide. The
strut's clevis bracket is pointing straight outward to the 6 o'clock position. For left side struts and
springs, the lower coil spring end should contact the strut's lower spring seat at the 7 o'clock
position. For right side struts and springs, the lower coil spring end should contact the strut's lower
spring seat at the 5 o'clock position.
10. Install the strut mount over the strut shaft and onto the top of the pivot bearing and upper seat
as shown. Loosely install the retaining nut on the
strut shaft.
11. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft
retaining nut. Next, install a 10 mm socket on the
hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft
retaining nut to a torque of 94 Nm (70 ft. lbs.).
12. Slowly release the tension from the coil spring by backing off the compressor drive fully. As the
tension is relieved, make sure the upper mount,
pivot bearing and upper seat align properly. Remove the clamp from the lower end of the coil
spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut
assembly from the spring compressor.
13. Install strut assembly on the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Specifications
Suspension Travel Bumper: Specifications
To Frame Rail ......................................................................................................................................
............................................... 33 Nm (290 inch lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Standard
Suspension Travel Bumper: Service and Repair Standard
There are two types of jounce bumpers available depending on which suspension option the
vehicle is equipped with.
REMOVAL-STANDARD
Jounce Bumper-Standard
The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a
weld nut located on the frame rail. 1. Using the proper tool, remove the bolt attaching the jounce
bumper to frame rail. 2. Remove the jounce bumper from the frame rail.
INSTALLATION-STANDARD
1. For installation, reverse the removal procedure. Tighten the jounce bumper mounting bolt to a
torque of 33 Nm (290 inch. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Standard > Page 5159
Suspension Travel Bumper: Service and Repair Heavy Duty
REMOVAL-HEAVY DUTY
Jounce Bumper-Heavy Duty
The jounce bumpers are serviced as an assembly. The jounce bumpers screw into a weld nut
located in the frame rail.
Bumper Replacement
1. Using slip-joint pliers grasp the base of the jounce bumper. Turn the base counterclockwise. 2.
Remove the jounce bumper from the frame rail.
INSTALLATION-HEAVY DUTY
1. For installation, reverse the removal procedure. Tighten the jounce bumper to a torque of 33 Nm
(290 inch. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information >
Specifications
Trailing Arm: Specifications
To Axle And Mounting Bracket Pivot Bolt
.............................................................................................................................................. 95 Nm
(70 ft. lbs.) Bracket To Body Attaching Bolt
..............................................................................................................................................................
61 Nm (45 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications Lubricant Type
Lubricant Type
Wheel Bearing Grease NLGI GC rated automotive grease
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
FRONT:
To Hub Bearing Nut .............................................................................................................................
............................................ 183 Nm (135 ft. lbs.)
REAR:
Stub Axle Nut .......................................................................................................................................
............................................ 224 Nm (180 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information >
Technical Service Bulletins > Spare Tire - Winch Precautions
Spare Tire: Technical Service Bulletins Spare Tire - Winch Precautions
BULLETIN NUMBER: 22-01-00
GROUP: Wheels & Tires
DATE: Mar.24, 2000
SUBJECT: Spare Tire Winches
MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE: THIS BULLETIN DOES NOT APPLY TO 1999 TOWN & COUNTRY VEHICLES BUILT
PRIOR TO JULY 2, 1998.
DISCUSSION: Beginning November 1,1999, the spare tire winch that is installed during vehicle
assembly is determined by the size/type of spare tire the vehicle is built with. DO NOT switch the
size/type of spare tire a vehicle is equipped with unless the spare tire winch is the correct one for
the size/type of spare tire to be used. Replacement of the spare tire winch may be required.
The spare tire winches are equipped with a secondary locking mechanism that may not function
properly if a full size spare or T125 70D15 Compact Spare is stored on a T145 90D16 compact
spare winch or vise-versa.
The illustration shows the correct application and identification for 1999-2000 NS-vehicle spare tire
winches:
PARTS INFORMATION
CAUTION: DO NOT SWITCH THE SIZE/TYPE OF SPARE TIRE A VEHICLE IS EQUIPPED WITH
UNLESS THE SPARE TIRE WINCH IS CORRECT FOR THE NEW SIZE/TYPE OF SPARE TIRE
AS CALLED OUT IN THE TABLE ABOVE. REPLACEMENT OF THE SPARE TIRE WINCH MAY
BE REQUIRED.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information >
Technical Service Bulletins > Page 5176
Spare Tire: Description and Operation
The temporary spare tire is designed for emergency use only. The original tire should be repaired
and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH
when the temporary spare tire is in use on the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 5185
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 5186
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 5187
TIRE/WHEEL MATCH MOUNTING
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 5188
WHEEL RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 5189
WHEEL BORE PILOT DIAMETERS
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 5190
HUB WHEEL PILOT DIAMETER
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 5191
HUB WHEEL PILOT RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 5192
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 5198
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 5199
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 5200
TIRE/WHEEL MATCH MOUNTING
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 5201
WHEEL RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 5202
WHEEL BORE PILOT DIAMETERS
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 5203
HUB WHEEL PILOT DIAMETER
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 5204
HUB WHEEL PILOT RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 5205
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-01-98 > Mar > 98 > Aluminum Wheels - Special Balance
Weights
Wheels: All Technical Service Bulletins Aluminum Wheels - Special Balance Weights
NO: 22-01-98
GROUP: Tires & Wheels
DATE: Mar. 13, 1998
SUBJECT: Balance Weights For Aluminum Wheels
MODELS: 1998 - 1999 (LH) Concorde/Intrepid/LHS/300M 1998 - 1999 (NS) Town &
Country/Caravan/Voyager
DISCUSSION:
Beginning with the 1998 model year LH and NS vehicle aluminum wheels have a unique balance
weight retention flange. This balance weight retention flange requires the use of special low profile
balance weights. The new balance weights are made by Perfect Equipment Company LLC, and
are available through their distributors and subsequent automotive jobbers.
The "LH Type Balance Weights" are available in 1/4 oz. Increments through the major distributors
listed:
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 22-01-98 > Mar > 98 > Aluminum Wheels - Special Balance
Weights
Wheels: All Technical Service Bulletins Aluminum Wheels - Special Balance Weights
NO: 22-01-98
GROUP: Tires & Wheels
DATE: Mar. 13, 1998
SUBJECT: Balance Weights For Aluminum Wheels
MODELS: 1998 - 1999 (LH) Concorde/Intrepid/LHS/300M 1998 - 1999 (NS) Town &
Country/Caravan/Voyager
DISCUSSION:
Beginning with the 1998 model year LH and NS vehicle aluminum wheels have a unique balance
weight retention flange. This balance weight retention flange requires the use of special low profile
balance weights. The new balance weights are made by Perfect Equipment Company LLC, and
are available through their distributors and subsequent automotive jobbers.
The "LH Type Balance Weights" are available in 1/4 oz. Increments through the major distributors
listed:
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Page 5215
Wheels: Description and Operation
Original equipment wheels are designed for proper operation at all loads up to the specified
maximum vehicle capacity.
All models use steel or aluminum drop center wheels. Every wheel has raised sections between
the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead
over these raised sections. In case of air loss the raised sections hold the tire in position on the
wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special
balance weights to fit on the thicker flange of the rim and special wheel clamps for the alignment
equipment. The wheel studs and nuts are designed for the specific wheel applications used on a
vehicle and must be replaced with equivalent parts. Do not use replacement parts of lesser quality
or of a substitute design from the original equipment part. All aluminum wheels have wheel stud
nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the
wheels. Vehicles that are equipped with bolt-on wheel covers use large nose wheel nuts. The
wheel nuts used on a vehicle equipped with bolt-on wheel covers are externally threaded so that
the wheel covers can be attached to the wheel nuts. Before installing a wheel, remove any buildup
of corrosion on the wheel mounting surface.
WARNING: INSTALLING WHEELS WITHOUT GOOD METAL-TO-METAL CONTACT COULD
CAUSE LOOSENING OF WHEEL LUG NUTS. THIS COULD ADVERSELY AFFECT THE
SAFETY AND HANDLING OF YOUR VEHICLE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Page 5216
Wheels: Testing and Inspection
Wheels must be replaced if they: Have excessive run out
- Are bent, dented or cracked
- Leak air
- Have damaged wheel lug holes
Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Original
equipment replacement wheels are available through the dealer. When obtaining replacement
wheels from any other source, they must be equivalent in load carrying capacity. The wheel
features (diameter, width, offset, brake clearance, and mounting configuration) must match the
original equipment wheels.
WARNING: FAILURE TO USE ORIGINAL EQUIPMENT REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF YOUR VEHICLE.
- REPLACEMENT WITH USED WHEELS IS NOT RECOMMENDED. THE SERVICE HISTORY
OF THE RIM MAY HAVE INCLUDED SEVERE TREATMENT OR VERY HIGH MILEAGE. THE
RIM COULD FAIL WITHOUT WARNING.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications Lubricant Type
Lubricant Type
Wheel Bearing Grease NLGI GC rated automotive grease
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component
Information > Specifications
Axle Nut: Specifications
FRONT:
To Hub Bearing Nut .............................................................................................................................
............................................ 183 Nm (135 ft. lbs.)
REAR:
Stub Axle Nut .......................................................................................................................................
............................................ 224 Nm (180 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Wheel Tightening Sequence
Wheel Fastener: Specifications Wheel Tightening Sequence
Wheel Torque Sequence - Master
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Wheel Tightening Sequence > Page 5228
Wheel Fastener: Specifications Lug Nut Torque
Lug Nut Torque ....................................................................................................................................
................................ 110 - 135 Nm (85 - 115 ft. lbs.) Hex Size ...........................................................
...........................................................................................................................................................
19 mm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Wheel Tightening Sequence > Page 5229
Wheel Fastener: Specifications Wheel Stud Size
Mounting Stud Size .............................................................................................................................
........................................................... M12 x 1.5 mm
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front
Wheel Fastener: Service and Repair Front
REMOVAL
CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the
studs CANNOT be hammered out of the hub flange. If a stud is removed by hammering it out of the
bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing
failure.
The following procedure and special tools shown MUST BE used when replacing wheel attaching
studs. The hub and bearing assembly does not require removal from the steering knuckle to
replace wheel attaching studs in the hub and bearing assembly. 1. Raise vehicle on jackstands or
centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the
vehicle.
Disc Brake Caliper Mounting
3. Remove the front caliper assembly from the front steering knuckle assembly.
4. Remove front rotor from hub, by pulling it straight off wheel mounting studs. 5. Install a lug nut on
the wheel stud to be removed from the hub and bearing assembly, so the threads on the stud are
even with end of lug nut.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 5232
Wheel Stud Removal From Hub/Bearing Assembly
Install Remover, Special Tool C-4150A on hub and bearing assembly flange and wheel stud. 6.
Tightening down on special tool will push wheel stud out of the hub and bearing assembly flange.
When shoulder of wheel stud is past flange
remove special tool from hub and bearing assembly. Remove lug nut from stud and remove wheel
stud from flange.
INSTALLATION
Installing Wheel Stud Into Hub And Bearing
1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on
wheel stud, then install a wheel lug nut on stud with flat
side of lug nut against washers.
2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing
assembly. When the head of the stud is fully seated against
the bearing flange, remove lug nut and washers from wheel stud.
3. Install the braking disk back on the hub and bearing assembly. 4. Install front brake caliper back
over braking disc and align with caliper mounting holes on steering knuckle. Install the caliper
adapter to steering
knuckle attaching bolts and torque to 19 Nm (168 inch. lbs.).
5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specification.
Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).
6. Lower vehicle to the ground.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 5233
Wheel Fastener: Service and Repair Rear
REMOVAL
CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the
studs cannot be hammered out of the hub flange. If a stud is removed by hammering it out of the
bearing flange, damage to the hub and bearing assembly will occur leading to premature hub and
bearing failure.
The following procedure and special tools shown MUST be used when replacing wheel attaching
studs. The hub and bearing assembly does not require removal from the rear axle for replacement
of the wheel attaching studs. 1. Raise vehicle on jackstands or centered on a frame contact type
hoist. 2. Remove the rear wheel and tire assembly. 3. Remove the rear brake drum.
Removing Wheel Stud From Hub And Bearing
4. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly so the
threads on stud are even with end of lug nut. Install
Remover, Special Tool C-4150A on hub and bearing assembly flange and wheel stud.
5. Tightening down on special tool will push wheel stud out of the hub and bearing assembly
flange. Remove lug nut from stud and remove wheel
stud from flange.
INSTALLATION
Installing Wheel Stud Into Hub And Bearing
1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on
wheel stud, then install a wheel lug nut on stud with flat
side of lug nut against washers.
2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing
assembly. When the head of the stud is fully seated against
the bearing flange, remove lug nut and washers from wheel stud.
3. Install the rear brake drum on the hub and bearing assembly. 4. Install wheel and tire assembly
on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to
half specification.
Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).
5. Lower vehicle to the ground.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Description
and Operation
Air Conditioning Switch: Description and Operation
AIR CONDITIONING SWITCH SENSE-PCM INPUT
When the air conditioning or defrost switch is put in the ON position and the low pressure switch,
combination valve, and high pressure switch close, the PCM receives an A/C input. After receiving
this input, the PCM activates the A/C compressor clutch by grounding the A/C clutch relay. The
PCM also adjusts idle speed to a scheduled RPM to compensate for increased engine load.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service
and Repair > Rear Heater - A/C Switch Lamp Replacement
Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Lamp Replacement
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel HVAC Control. Refer
to Radio Bezel and HVAC Control Replacement.
Rear Heater - A/C Switch Lamp Bulb
3. Rotate bulb socket counterclockwise one quarter. 4. Pull bulb socket from switch.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service
and Repair > Rear Heater - A/C Switch Lamp Replacement > Page 5240
Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Replacement
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel and HVAC Control.
Rear Heater - A/C Switch
3. Remove screw holding rear heater-A/C switch to radio bezel HVAC Control. 4. Disengage hook
holding bottom of switch to radio bezel HVAC Control. 5. Remove switch from radio bezel HVAC
Control.
INSTALLATION
For instrument, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Testing and Inspection > Actuator Calibration and Diagnostics
Air Door Actuator / Motor: Testing and Inspection Actuator Calibration and Diagnostics
NOTE: Do not run actuators unless they are properly mounted on the HVAC control module.
Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and
INTERMITTENT LED's will flash alternately during the test. The control will cycle the Blend
actuator(s) to the Heat stop first then back to Cold. After the Blend actuator(s) have been calibrated
the Mode actuator will be cycled to Defrost and then to Panel. Successful calibration is defined as
actuator travel falling within their minimum and maximum limits.
Blend/Passenger Actuator Background
The Blend/Passenger Actuator can move the temperature door in two directions. When the voltage
at Pin 12 of the control module is high, about 11.5 volts, and the voltage at Pin 17 is low, about 1.5
volts, the door will move towards the Heat position. When Pin 17 is High and Pin 12 is Low the
door will move towards the Cold position. When both Pins are high or both Pins are low, the
actuator will not move. The Blend/Passenger feedback signal is a voltage signal that is supplied by
the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the
Cold position. As the position of the Blend/Passenger actuator changes, so will the feedback
signal. The feedback signal is necessary for the correct positioning of the temperature door.
Driver Actuator Background
The Driver Actuator can move the temperature door in two directions. When the voltage at Pin 15
of the control module is high, about 11.5 volts, and the voltage at Pin 13 is low, about 1.5 volts the
door will move towards the Cold position. When Pin 13 is High and Pin 15 is Low the door will
move towards the Heat position. When both Pins are high or when both Pins are low, the actuator
will not move. The Driver feedback signal is a voltage signal that is supplied by the actuator to the
control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As
the position of the Driver Actuator changes, so will the feedback signal. The feedback signal is
necessary for the correct positioning of the temperature door.
Mode Actuator Background
The Mode actuator can move the mode door in two directions. When the voltage at Pin 18 of the
control module is high, about 11.5 volts, and the voltage at Pin 12 is low, about 1.5 volts the door
will move towards the Panel position. When Pin 12 is High and Pin 18 is Low the door will move
towards the Defrost position. When both Pin are high or when both Pins are low, the actuator will
not move. The Mode door feedback signal is a voltage signal that is supplied by the actuator to the
control. The signal will be about 4.5 volts in the Panel position and 0.5 volts in the Defrost position.
As the position of the Mode actuator changes, so will the feedback signal. The feedback signal is
necessary for the correct positioning of the mode door.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Testing and Inspection > Actuator Calibration and Diagnostics > Page 5246
Air Door Actuator / Motor: Testing and Inspection Actuator Calibration/Diagnostics and Cool Down
Test
GENERAL INFORMATION
If the HVAC control module is replaced, the Calibration Diagnostic and Cooldown tests will need to
be performed. Once this group of tests have successfully passed, they can be performed
individually. The engine must be running during the test to provide hot coolant for the heater, A/C
compressor operation and to assure that the actuators are calibrated correctly. The HVAC control
module is capable of troubleshooting the system in approximately 120 seconds. If a condition is
detected, an error code is displayed. The error code cannot be erased until the condition is
repaired and the diagnostic test is performed.
CAUTION: Do not remove the actuators from the Heater-A/C unit assembly with power applied.
Removal should only be done with the Ignition OFF. The actuators have no mechanical stops to
limit the travel. If the actuator rotates and is not connected to the unit assembly, it will become out
of calibration.
Actuator Calibration
Radio Bezel And HVAC Control
Radio Bezel And HVAC Control, Rear Blower Motor Switch And Zone Control
Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the
actuators, HVAC control module and its linkages. In vehicle calibration can be entered from the
control's front panel. If the REAR WIPE and INTERMITTENT LED's flash simultaneously when
Ignition is cycled ON, the actuators have not been calibrated or during the previous calibration a
failure occurred. Diagnostics will always occur during Calibration Diagnostic and Cooldown test.
Diagnostics
During the Actuator calibration, diagnostics are performed on the actuators and evaporator
temperature Fin Sensor. Once diagnostics are completed the REAR WIPER and INTERMITTENT
LED's will flash to indicate either a successful calibration or the appropriate fail code(s). At this time
manual testing of the Blend, Mode and Driver (if equipped) potentiometers can be performed. If a
failure is detected during Diagnostics a fault will be set in the control. When Ignition is cycled OFF
and then ON or Diagnostics is aborted, the REAR WIPER and INTERMITTENT LED's will flash
simultaneously showing that a failure has occurred. The control will not indicate the fail code, but
only that a failure had occurred during the last diagnostics test. The only way to clear the failure
codes is repeat the Calibration Diagnostic and Cooldown test, after all repairs are completed.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Testing and Inspection > Actuator Calibration and Diagnostics > Page 5247
Cooldown Test
This test has been designed for performance testing of the A/C system at the manufacturing
facility. If the HVAC control module is replaced, the Cooldown test will occur during Calibration test.
Cooldown will not occur on Heater Only units. During the Cooldown test the control will monitor the
temperature of the Fin Sensor. The A/C system must be able to bring the evaporator temperature
down a predetermined minimum amount in less than 2 minutes.
Calibration/Cooldown LED Display Codes
Calibration/Cooldown LED Display Codes
See chart for definition of flashing LED's. If no problems are found, the control functions normally.
Calibration/Diagnostics Test Entry
To Initiate Tests:
- Set Blower motor ON HIGH
- Set Mode position to Panel
- Open all A/C outlets
- Set Temperature to Cold (Both slide pots if equipped)
- Depress WASH and REAR WIPER button simultaneously for 5 Seconds (Until all LED's light)
Results:
- All LED's will turn on for 5 Seconds
- Calibration Test is running when REAR WIPER and INTERMITTENT are alternately flashing.
Cooldown test is running if A/C and RECIRC are alternately flashing.
- Acceptable results is REAR WIPER LED is the only LED flashing. Push Rear Wiper to exit.
- After all tests have passed, Calibration Diagnostics and Cool down can be run separately.
Cooldown Test Entry
To Initiate Tests:
- Set Blower motor ON HIGH
- Set Mode position to Panel
- Open all A/C outlets
- Set Temperature to Cold (Both slide pots if equipped)
- Depress WASH and A/C simultaneously for 5 Seconds
NOTE: Prior to start of test, If the evaporator is already cold, the system will fail test. To correct,
operate system with A/C OFF and the blower motor ON high for three minutes prior to starting test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Testing and Inspection > Actuator Calibration and Diagnostics > Page 5248
Results:
- All LED's will turn on for 5 Seconds
- Cooldown Test is running when A/C and RECIRC. are alternately flashing. If A/C and RECIRC.
are flashing simultaneously, Cooldown has failed.
Calibration Diagnostics And Cooldown Abort
Test can be aborted by doing one of the following:
- Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons.
- Cycling Ignition OFF and then ON.
- Control will automatically abort after 15 minutes from the time Calibration Diagnostics and
Cooldown was entered.
The HVAC control module will return to normal operation or may indicate unsuccessful Calibration.
Diagnostics or Cooldown test by LED's flashing simultaneously.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Testing and Inspection > Page 5249
Air Door Actuator / Motor: Adjustments
1. Install lower FLOOR door actuator gear to housing. Match master spline of FLOOR door
actuator gear to master spline on door. 2. Install cam wheel. Align cam wheel track to FLOOR door
actuator gear. 3. Align cam wheel slot with the post on the distribution housing marked "1". 4.
Install PANEL door actuator gear. Align master spline of PANEL door actuator gear to master
spline on PANEL door. Position actuator gear
within cam wheel track.
5. Install DEFROST door actuator gear to housing. Match master spline of DEFROST door
actuator to master spline on DEFROST door. Position
actuator gear within cam wheel track.
6. Reinstall housing in vehicle. 7. Perform the HVAC control Calibration Diagnostic and Cooldown
test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement
Air Door Actuator / Motor: Service and Repair Blend Door Actuator Replacement
REMOVAL
Side View Of HVAC With Actuators
The air conditioning system can be equipped with either a standard, single blend-air door actuator,
or it can be equipped with dual actuators. The dual system has separate blend-air controls. This
allows for separate control of the driver's side air, and the passenger side air. 1. Remove the lower
left side steering column cover. Refer to Instrument Panel and Systems.
ABS Control Module
2. Remove ABS control module. 3. Remove blend-air actuator connector.
Blend-Air Actuator
4. Remove blend-air actuator.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5252
INSTALLATION
1. For installation, reverse the above procedures. 2. Perform the HVAC Control Calibration
Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5253
Air Door Actuator / Motor: Service and Repair Mode Door Actuator Replacement
REMOVAL
1. Remove the Instrument Panel. Refer to Instrument Panel and Systems for Replacement.
ABS Control Module
2. Remove ABS control module.
Mode Door Actuator Connector
3. Remove mode actuator connector.
Mode Door Actuator
4. Remove mode door actuator.
INSTALLATION
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5254
1. For installation, reverse the above procedures. 2. Perform the HVAC control Calibration
Diagnostic and Cooldown test.
REMOVAL
1. Remove A/C unit. 2. Place unit on bench. 3. Remove mode door actuator connector. 4. Remove
mode door actuator mounting screws and remove actuator.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement > Page 5255
Air Door Actuator / Motor: Service and Repair Recirculation Air Door Actuator Replacement
REMOVAL
1. Pull back on carpeting on the right lower floor. 2. Remove Recirc. door actuator connector.
Recirculation Door Actuator
3. Remove (3) mounting screws for Recirc. actuator. 4. Remove Recirc. actuator. 5. Disengage
actuator linkage at Recirc. door. 6. Remove actuator from vehicle.
INSTALLATION
1. For installation, reverse the above procedures. 2. Perform the HVAC control Calibration
Diagnostic and Cooldown test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Description and Operation
Air Duct: Description and Operation
SYSTEM OPERATION
Air Distribution Ducts The air distribution ducts for the A/C, Heater, Defroster, and Second Seating
Air Distribution are not serviceable in vehicle. The procedures for service of these ducts are
covered in Instrument Panel and Gauges.
The only ducts that are serviceable in the vehicle are the side window demister ducts and the ducts
that feed the front door outlets for the first rear passenger(s) seating.
Side Door Heater A/C Outlets
Door Outlets
The driver's and passenger side doors have supplemental air outlets and duct work. The air is
channeled from the instrument panel to the door duct and either to the lower floor or upper door
outlets. The air can be adjusted to blow on the first rear passenger seat(s).
Side Window Demister
Demister Inlet
The side window demisters direct air from the heater assembly. The outlets are located on the top
forward corners of the front door panels. The demisters operate when the control mode selector is
on FLOOR, MIX or DEFROST setting.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air
Distribution Duct (A/C) Replacement
Air Duct: Service and Repair Air Distribution Duct (A/C) Replacement
REMOVAL
Quarter Trim Panel
1. Remove quarter trim panel, D-pillar, and headliner. 2. Remove screws securing D-pillar duct to
quarter panel. Pull duct up and away from unit.
Rear Crossover Duct
3. Remove screws securing duct to rear header.
Upper A/C Duct
4. Remove screws securing duct to right and left rails.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air
Distribution Duct (A/C) Replacement > Page 5261
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air
Distribution Duct (A/C) Replacement > Page 5262
Air Duct: Service and Repair Air Distribution Duct (Heater) Replacement
REMOVAL
Quarter Trim Panel
Rear Heat-A/C Unit
1. Remove quarter trim panel and D-pillar. 2. Remove screws securing lower heat duct to housing.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air
Distribution Duct (A/C) Replacement > Page 5263
Air Duct: Service and Repair Side Window Demister Duct Replacement
REMOVAL AND INSTALLATION
LEFT SIDE
Left Side Demister Duct
The LEFT side window demister duct is a two piece design. The left side has a long duct that
attaches to an intermediate duct and then to the distribution housing. The duct is located on top of
the instrument panel. To service the duct, remove the I/P cover and remove duct
retainers/fasteners.
RIGHT SIDE
Right Side Demister Duct
The demister duct on the right side is a one piece design. It is one long duct that attaches to the
distribution housing. The duct is located on top of the instrument panel and it is not serviceable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
Air Register: Service and Repair
REMOVAL
Separate barrel from bezel by pulling outward.
INSTALLATION
For installation, push the outlet firmly into the opening until it locks into place.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations
Ambient Temperature Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 5270
Ambient Temperature Sensor / Switch HVAC: Diagrams
Ambient Temperature Sensor
Ambient Temperature Sensor (Sensor Side)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 5271
Ambient Temperature Sensor / Switch HVAC: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Raise and support vehicle on safety stands.
3. From behind front bumper fascia, remove screw holding sensor to radiator closure panel. 4.
Remove sensor from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and
Inspection
Blower Motor: Testing and Inspection
Vibration and/or Noise Diagnosis
The blower speed switch, in conjunction with the resistor block, supplies the blower motor with
varied voltage.
CAUTION: Stay clear of the blower motor and resistor block (Hot). Do not operate the blower motor
with the resistor block removed from the heater A/C housing.
Blower Motor Noise/Vibration Diagnosis
Refer to the Blower Motor Vibration/Noise chart for diagnosis.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor and Wheel Assembly Replacement
Blower Motor: Service and Repair Blower Motor and Wheel Assembly Replacement
REMOVAL
1. Remove glove box. Refer to Instrument Panel and Systems.
Blower Motor Cover
2. Remove (4) hex head screws to blower motor cover. 3. Disconnect blower motor wiring.
Wiring Grommet
Feeding Wiring Through Housing
4. Remove grommet for wiring. Feed wiring through blower housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor and Wheel Assembly Replacement > Page 5277
Blower Motor Screws
5. Remove mounting screws for blower motor. 6. Allow the blower assembly to drop down, and
remove assembly from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor and Wheel Assembly Replacement > Page 5278
Blower Motor: Service and Repair Blower Motor Wheel Replacement
REMOVAL AND INSTALLATION
The blower motor wheel is not serviced separately If the wheel needs to be replaced it is serviced
as an assembly of the blower motor. For service procedure information, refer to Blower Motor
Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor and Wheel Assembly Replacement > Page 5279
Blower Motor: Service and Repair Rear Blower Motor Replacement
REMOVAL
1. Remove the right quarter trim panel and D-pillar trim.
Blower Motor
2. Remove (5) screws securing the blower motor housing to the rear of the HVAC housing (one
screw located on evaporator cover). 4. Disconnect blower motor wiring connector.
INSTALLATION
For installation reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Component Locations
Blower Motor Relay: Component Locations
Power Distribution Center -- Sheet 8w-10-2
Rear Blower Relay
Rear Blower Motor Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Component Locations > Page 5284
This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Component Locations > Page 5285
Blower Motor Relay: Connector Locations
Power Distribution Center
Front Blower Motor Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description
and Operation > Front Blower Motor Relay
Blower Motor Relay: Description and Operation Front Blower Motor Relay
Circuit Operation
Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the
HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1.
The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power
Distribution Center (PDC).
The coil side of the relay is energized when the ignition switch is in the RUN position only. Power
for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the
relay
Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit
A22.
Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl
panel.
Ground for the blower motor is controlled through the blower motor resistor and the blower motor
switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description
and Operation > Front Blower Motor Relay > Page 5288
Blower Motor Relay: Description and Operation Rear Blower Relay
Circuit Operation
Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp
fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear
blower motor passes through the temperature sensor and one or more resistors, depending on
speed selection.
Two switches operate the rear blower motor by supplying ground; the front control switch and the
rear control switch. The front control switch must be in the ON position for the rear control switch to
operate the rear blower motor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations
Blower Motor Resistor: Locations
Connector Locations
Resistor Block Location
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Page 5292
Blower Motor Resistor: Description and Operation
SYSTEM OPERATION
Rear Blower Resistor Block The rear blower motor resistor is not serviceable separately. The
resistor is integral to the blower motor. If resistor is faulty, it is necessary to replace the complete
blower motor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Page 5293
Blower Motor Resistor: Service and Repair
REMOVAL
1. Open hood. 2. Disconnect and isolate negative battery cable.
Resistor Block Location
3. Locate and remove the wire connector from the blower resistor block. Block is located at the
back of the engine compartment on the passenger
side of the vehicle under the wiper module.
NOTE: It may not necessary to remove the wiper module to access the resistor block.
Resistor Block Removal
4. Using a long flat blade screwdriver, gently push in on drivers side of resistor. Be careful to catch
the inner release tang and gently pry outward.
WARNING: THE RESISTOR BLOCK MAY BE HOT. DO NOT ATTEMPT TO SERVICE THE
RESISTOR BLOCK IF THE SYSTEM HAS BEEN RUNNING RECENTLY. LET THE SYSTEM
COOL DOWN BEFORE REPAIRS ARE INITIATED.
5. Remove resistor block by inserting a flat blade pry tool on the side of the resistor block and
pushing inward. Two guide lines are shown on the
right hand edge of the resistor block to help guide the blade position. This will release the clips on
the side of the resistor block. Pull resistor block out.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Page 5294
INSTALLATION
For installation, reverse the above procedures. Make sure the "TOP" lettering is on the top of the
resistor. The coils on the Resistor Block should not be contacting one another. Before installation,
gently separate the coils (with fingers only) if one coil is contacting another.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description
and Operation
Blower Motor Switch: Description and Operation
SYSTEM OPERATION
Rear Blower Speed Switch The rear blower speed switch controls the rear blower with the choice
of low and high speeds. when the switch is on it allows the blower speed switch located on the rear
headliner to control rear blower speed. This switch will override the rear headliner blower switch.
For operation instructions refer to the Owner's Manual. The rear blower speed switch is serviced
separately from the A/C control module. For service procedures, refer to Instrument Panel And
Gauges.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Electrical Specifications
Compressor Clutch: Electrical Specifications
Draw 2.2 amps @ 12 V ±0.5V @ 70°F
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Electrical Specifications > Page 5303
Compressor Clutch: Mechanical Specifications
Clutch Air Gap .....................................................................................................................................
........................... 0.41 - 0.79 mm (0.016 - 0.031 in.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 5304
A/C Compressor Clutch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 5305
Compressor Clutch: Service and Repair
REMOVAL AND INSTALLATION
After a new clutch has been installed, check the voltage and amperage to the clutch (determine it
to be satisfactory). Then cycle the A/C clutch approximately 20 times (5 sec. on and 5 sec. off). For
this procedure, set the system to the A/C mode, using high blower, and engine rpm at 1500-2000.
This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch
torque capability
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams
A/C Compressor Clutch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 5309
Compressor Clutch Coil: Testing and Inspection
The air conditioning compressor clutch electrical circuit is controlled by the Powertrain Control
Module. It is located in the engine compartment outboard of the battery If the compressor clutch
does not engage verify refrigerant charge.
If the compressor clutch still does not engage check for battery voltage at the pressure transducer
located on the liquid line. If voltage is not detected, refer to:
- Powertrain Diagnostic Procedures for diagnostic information.
If voltage is detected at the pressure transducer, connect pressure transducer and check for
battery voltage between the compressor clutch connector terminals.
If voltage is detected, perform A/C Clutch Coil Tests.
Tests
1. Verify battery state of charge. (Test indicator in battery should be green). 2. Connect an
ampmeter (0-10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0-20 volt
scale) with clip leads measuring
voltage across the battery and A/C clutch.
3. With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle.
4. The A/C clutch should engage immediately and the clutch voltage should be within two volts of
the battery voltage. If the A/C clutch does not
engage, test the fuse.
5. The A/C clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at
clutch coil. This is with the work area temperature
at 21° C (70° F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical
accessories until voltage reads below 12.5 volts.
6. If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 4
amperes or more, the coil is shorted and should be
replaced. If the coil voltage is not within two volts of the battery voltage, test clutch coil feed circuit
for excessive voltage drop.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 5310
Compressor Clutch Coil: Service and Repair
REMOVAL
Compressor Shaft Bolt And Clutch Plate
1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the
clutch plate to aid in bolt removal.
CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front
plate as this may damage the front plate assembly.
Clutch Plate And Shim(s)
2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim(s).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 5311
Removing Pulley Snap Ring
3. Remove pulley retaining snap ring with snap ring pliers (C-4574), and slide pulley assembly off
of compressor. 4. Remove coil wire clip screw and wire harness.
Clutch Coil Snap Ring
5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor
housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and
front plate should be replaced if there is excessive wear or
scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and
remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is
leaking and will have to be replaced.
7. Check bearing for roughness, excessive leakage or grease. If grease from bearing has
contaminated the faces of the pulley or front plate, they
should be replaced. If the bearing is rough or binds, replace clutch pulley and front plate assembly.
CAUTION: The clutch pulley and the front plate were mated at the factory by a burnishing
operation. No attempt should be made to separately replace either part. This will result in clutch
slippage due to insufficient contact area.
INSTALLATION
1. Align pin in back of field coil with hole in compressor end housing, and position field coil into
place. Make sure that lead wires are properly
routed, and fasten with the wire clip screw.
2. Install field coil retaining snap ring with snap ring pliers. The bevel side of the snap ring facing
outward. Also both snap ring eyelets must be to the
right or left of the pin on compressor. Press snap ring to make sure it is properly seated in the
groove.
CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Diagrams > Page 5312
Installing Pulley Assembly
3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the
friction surface.
CAUTION: Do not mar the pulley frictional surface.
4. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press the
snap ring to make sure it is properly seated in the
groove.
5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be
used. If not, place a trial stack of shims, 1 mm
(0.040 in.) thick, on the shaft against the shoulder.
6. Install front plate assembly onto shaft. 7. With the front plate assembly tight against the shim(s),
measure the air gap between front plate and pulley face with feeler gauges. The air gap
should be between 0.5 and 0.9 mm (0.020 and 0.035 inch) If proper air gap is not obtained, add or
subtract shims until desired air gap is obtained.
8. Install compressor shaft bolt. Tighten to 16.5 ± 2 Nm (155 ± 20 in. lbs.).
NOTE: Shims may compress after tightening shaft nut. Check air gap in four or more places to
verify if air gap is still correct. Spin pulley for final check.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Component Locations
Compressor Clutch Relay: Component Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Component Locations > Page 5317
Power Distribution Center -- Sheet 8w-10-2
The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is
located in the engine compartment next to the battery. A label affixed to the underside of the PDC
cover identifies the relays and fuses in the PDC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Component Locations > Page 5318
Compressor Clutch Relay: Connector Locations
Power Distribution Center
A/C Compressor Clutch Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Page 5319
Compressor Clutch Relay: Description and Operation
AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT
The PCM operates the air conditioning clutch relay ground circuit, The radiator fan control module
supplies battery power to the solenoid side of the relay. The air conditioning clutch relay will not
energize unless the radiator fan control module energizes. The radiator control module energizes
when the air conditioning or defrost switch is put in the ON position and the low pressure switch,
combination valve, and high pressure switch close.
With the engine operating, the PCM cycles the air conditioning clutch on and off when the A/C
switch closes with the blower motor switch in the On position. When the PCM senses low idle
speeds or wide-open-throttle through the throttle position sensor, it de-energizes the A/C clutch
relay. The relay contacts open, preventing air conditioning clutch engagement.
The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is
located in the engine compartment next to the battery. A label affixed to the underside of the PDC
cover identifies the relays and fuses in the PDC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation
Condenser HVAC: Description and Operation
SYSTEM OPERATION
Condensate Drain Condensation from the evaporator housing is drained through the dash panel
and on to the ground. This drain must be kept open to prevent water from collecting in the bottom
of the housing.
If the drain is blocked condensate cannot drain, causing water to back up and spill into the
passenger compartment. It is normal to see condensate drainage below the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair > Front A/C Condenser
Condenser HVAC: Service and Repair Front A/C Condenser
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL
1. Recover A/C system refrigerant.
Liquid Line
2. Remove liquid line at filter-drier.
Filter-Drier
3. Remove (2) bolts attaching filter-drier to radiator module. 4. Remove upper radiator
crossmember. 5. Tilt radiator rearward.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair > Front A/C Condenser > Page 5325
Upper Discharge Line
6. Remove upper discharge line at condenser. 7. Through fascia, remove lower liquid line from
filter-drier. 8. Remove (2) lower condenser mounting bolts. 9. Remove (2) upper mounting bolts.
Condenser Removal
10. Remove condenser from vehicle.
INSTALLATION
NOTE: Inspect Cooling Module for presence of seals. Verify seals are available for re-installation.
1. Before installation, replace all O-rings and gaskets, coat all sealing surfaces with approved
wax-free refrigerant oil. Then, reverse the above
procedures,
2. Torque the following components to specifications:
- Liquid line at filter/drier - 45 in. lbs. ± 10.
- Upper discharge line at condenser - 180 in. lbs. ± 20.
- Lower liquid line to condenser - 180 in. lbs. ± 20.
- (2) lower, condenser mounting bolts - 45 in. lbs. ± 10.
- (2) upper, condenser mounting bolts - 45 in. lbs. ± 10.
- Tube fitting - 65 in. lbs. ± 5.
3. Evacuate and charge system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair > Front A/C Condenser > Page 5326
Condenser HVAC: Service and Repair Rear A/C Auxiliary Condenser
If vehicle is equipped with rear heater and air conditioning, it will be equipped with an auxiliary
condenser. The auxiliary condenser is mounted on the primary condenser in front of the radiator.
Both condenser must be removed as an assembly and then separated.
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
The condenser assembly must first be removed from vehicle. Refer to CONDENSER ASSEMBLY
Replacement for service procedures.
REMOVAL
1. After condenser assembly removal, place on bench for disassembly. 2. Remove (1) bolt to liquid
line on auxiliary condenser.
Rear Heat-A/C Auxiliary Condenser
3. Remove (4) attaching bolts and separate auxiliary from primary condenser.
INSTALLATION
1. Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved
wax-free refrigerant oil. Then, reverse the above
procedures.
2. Verify seals are in place on either side and on top of the radiator. 3. Evacuate and recharge
system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Electrical Systems - Feature Changes
Control Assembly: Technical Service Bulletins Electrical Systems - Feature Changes
NO: 08-34-98 Rev. B
GROUP: Electrical
DATE: Oct. 9, 1998
SUBJECT: 1999 Electrical Feature Changes
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-34-98 REV. A, DATED
JUL. 24, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE REMOTE KEYLESS
ENTRY (RKE) KEY FOB/TRANSMITTER PROGRAMMING PROCEDURE AND ADDITIONAL
INFORMATION ABOUT THE HEAT VENTILATION AIR CONDITIONING (HVAC) CONTROL
HEAD AND POWER DISTRIBUTION CENTER (PDC).
MODELS:
1999 (NS) Town & Country/Caravan/Voyager
DISCUSSION:
The HVAC control head, "gold dust" instrument cluster, and remote radio control features were
introduced in March of 1998 on the 1999 Town & Country Limited. All other features listed entered
vehicle production July 2, 1998 (MDH 0702XX).
Ignition Off Draw (IOD) Fuse Installation
Previously the IOD fuse was taped under the PDC cover. Starting with the 1999 model year, the
IOD fuse will be located in a spare IOD fuse holder cavity next to the IOD fuse location. Prior to the
vehicle being delivered to the customer, the fuse from the spare cavity must be installed into the
IOD fuse slot in order for the M1 feed to be active.
Remote Radio Controls (RDZ)
The Body Control Module (BCM) monitors steering wheel radio switch status (volume up/down,
seek up/down, and preset station change). The BCM then communicates this information to the
radio over the CCD bus.
Remote Keyless Entry (RKE) Peanut Key Fob/Transmitter
A new key fob and RKE module are used. Pinout for the RKE module is the same as 1998. **RKE
and RKE programming is inhibited when the gearshift lever is not in Park.** The system assures no
duplicate transmissions. This prevents unauthorized individuals from recording the transmitted
signal and coming back later, playing back the "stolen" signal and thus gaining access to the
vehicle. The key fob/transmitter programming procedure has changed and is as follows, **if an
already programmed key fob/transmitter is available, otherwise a scan tool (DRBIII(R)) must be
used to access the programming mode**
1. **With the transmission in Park**, turn the ignition switch to the ON position.
2. Press and hold the Unlock button **of an already programmed key fob/transmitter** for a
minimum of **5** seconds to a maximum of 10 seconds. During the Unlock button **5**-10 second
time frame press the Panic button, then release both buttons at the same time. The RKE system is
now in the program mode for **30 seconds. A short chime will come from the BCM indicating the
programming mode has been activated.**
3. Program the key fob/transmitter one by pressing and releasing the lock and unlock buttons at the
same time, then press and release any button on the key fob/transmitter. **A short chime will
sound indicating a key fob/transmitter has been successfully programmed.**
4. Perform step 3 on **any remaining key fob/transmitters within the 30 second** time frame.
5. The RKE system will exit the programming mode after **30 seconds** or if the ignition is turned
OFF. **A chime will sound after 30 seconds has elapsed or if the ignition switch is turned OFF
indicating the programming mode has been exited.**
HVAC Control Head
The HVAC control head communicates on the CCD bus and receives the A/C head pressure
message from the Powertrain Control Module (PCM).
The control head automatically resets to fresh air at ignition ON to help reduce odor. Vehicles are
shipped from the assembly plant with the recirculation
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Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Electrical Systems - Feature Changes > Page 5331
control programmed to cancel the recirculation mode when the ignition key is turned OFF and will
reset to fresh/outside air mode when the ignition key is turned ON. The frequent use of outside air
helps to keep odors from building up within the A/C-heater housing. It is recommended the
recirculation mode be used as little as possible, especially in humid climates. For vehicle operators
in hot and dry climates or people who are allergic to pollen and find frequent use of the recirculation
mode necessary, the recirculation control can be programmed to not automatically reset to the
fresh/outside air mode by using the following procedure:
1. Start the engine and turn the A/C blower switch to any position other than the OFF or LOW
speed position.
2. Set the mode control to panel/face.
3. Turn the ignition key to the OFF position.
4. Depress and hold the recirculation button in.
5. Start the engine, continue to hold the recirculation button in.
6. The recirculation indicator light will flash repeatedly, when the light stops flashing release the
recirculation button. Programming is now complete. If the light stays ON, the system will
"remember" the recirculation mode when the ignition is turned ON. If the light goes OFF, the
system will reset to fresh/outside air each time the ignition is turned ON.
The HVAC control head has an automatic calibration feature **which activates after the ignition is
turned ON and if the control head determines via the CCD bus, the VIN is different than the VIN the
control head previously detected, such as when a new control head is being installed or a control
head is being swapped from one vehicle to another.** The automatic calibration process takes
about 45 seconds to complete.
Rear Wiper CCD Driven
The HVAC control head communicates rear wiper switch status over the CCD bus to the Body
Control Module (BCM).
Autostick Available On Dodge ES
The Autostick feature allows the driver to control the vehicles transmission upshifts and downshifts
by toggling a switch located near the end of the gearshift lever. The system also incorporates an
Overdrive (O/D) OFF button at the end of the gearshift lever that allows the driver to switch
between Overdrive ON and Overdrive OFF **when the gearshift lever is in the "D" position.**
Instrument Clusters
Autostick Cluster
A unique cluster has been introduced to support the new Dodge ES model with Autostick. The
cluster content and appearance is the same as the premium cluster (shown in the owners manual)
except for the unique gear select indicator display. The gear select indicator display changes from
the typical "P-R-N-D-3-L" to "P-R-N-D-1-2-3-4" for Autostick.
Town & Country Limited Cluster
A unique cluster has been introduced to support the new Chrysler Town & Country Limited model.
The cluster content is the same as the premium cluster except for its unique appearance. The
cluster offers a "gold dust" gauge appearance with red gauge pointers during daylight conditions. At
night, the numbers, letters and/or symbols are illuminated using traditional blue-green lighting.
Electrical Connector
New Cluster Wiring Connector
A new 13-way connector system is used for all NS instrument clusters. The connector on the wire
harness side includes a Connector Position Assurance (CPA) secondary latch (orange), which
assures the connector will not become dislodged (or loose) when seated properly. The connector
includes blade type terminals, which offer greater strength and reduces the potential for bent
terminals.
NOTE:
TO DISCONNECT THE WIRE HARNESS CONNECTOR FROM THE CLUSTER THE CPA LATCH
ON THE WIRING HARNESS CONNECTOR MUST BE UNLOCKED BEFORE DEPRESSING THE
RELEASE LATCH.
New Connectors for All Door and Rear Quarter Speakers
There are new speaker connectors for all door and rear quarter speakers. The new connectors
provide a direct connect (versus pigtail). This improves the manufacturing process and reduces risk
of rattles.
Fog Lamps
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Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Electrical Systems - Feature Changes > Page 5332
A direct wiring connection to fog lamps (no pigtail) is now used.
Ignition Coil
The primary connector has been changed from a pin/sleeve type to a blade type connector for
improved reliability.
EATX Transmission Range Sensor (TRS)
A new blade type TRS connector **will be used for 1999 as a running change. Early production
1999 vehicles will use the 1998 type sensor with a jumper harness.**
O2 Sensor
This includes a gold terminal and an isolated return signal to the PCM (pin 27). This change
improves reliability.
Wiper Motor
The connector is changed from a 10-way to a 4-way.
Stamped Battery Cable Terminal
The new battery cable terminal requires less torque. The new torque specification is 3.3 - 4.5 Nm
(30 - 40 in. lbs.).
BCM Wiring Change
Air Bag Warning Chime
The BCM will sound a single chime if both of the following conditions are met:
1. Ignition has been in run/start position greater than 10 seconds.
2. The air bag lamp status message (sent from the air bag module) indicates lamp on.
In order for the chime to be able to sound again (reset monitor), the BCM must receive input
indicating the vehicle speed is zero and the air bag lamp is off.
**Power Distribution Center (PDC)
As a running change, expected to take place the first week of January 1999, a revised PDC will go
into vehicle production. Although some fuse, relay, and connector positions will be different, the
pin-outs and diagnostics for the individual connectors/components will remain the same.**
POLICY: Information Only
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Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Page 5333
Control Assembly: Locations
HVAC Control Module
The control module is included in the A/C control head located on the instrument panel.
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Technical Service Bulletins > Page 5334
Control Assembly: Diagrams
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Technical Service Bulletins > Page 5335
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Technical Service Bulletins > Page 5336
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Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Technical Service Bulletins > Page 5337
Control Assembly: Description and Operation
HVAC Control Module
HVAC Control Module
The HVAC control module regulates the operation of the various actuator motors. The actuator
motors are used to move the mode, blend-air, and Recirculation doors.
The control module is included in the A/C control head located on the instrument panel. The control
head includes the blower speed switch, rear wiper and washer operation, front & rear window
defogger, recirculation door operation, and A/C compressor operation if equipped.
NOTE: The Recirculation function on the HVAC control module automatically defaults to the OFF
position after a ignition key cycle. To reactivate the Recirculation function, the Recirculation button
must be repressed.
NOTE: The rear blower speed switch is serviced separately from the control head.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Calibration -- May Be Needed After Replacing Control Unit
Control Assembly: Testing and Inspection Calibration -- May Be Needed After Replacing Control
Unit
GENERAL INFORMATION
If the Heating Ventilation and Air Conditioning (HVAC) control module is replaced, the Calibration
Diagnostic and Cooldown tests will need to be performed. Once this group of tests have
successfully passed, they can be performed individually. The engine must be running during the
test to provide hot coolant for the heater, A/C compressor operation and to assure that the
actuators are calibrated correctly. The HVAC control module is capable of troubleshooting the
system in approximately 120 seconds. If a condition is detected, an error code is displayed. The
error code cannot be erased until the condition is repaired and the diagnostic test is performed.
Check wiring before replacing components.
CAUTION: Do not remove the actuators from the Heater-A/C unit assembly with power applied.
Removal should only be done with the Ignition OFF. The actuators have no mechanical stops to
limit the travel. If the actuator rotates and is not connected to the unit assembly, it will become out
of calibration.
Radio Bezel and HVAC Control
Radio Bezel and HVAC Control w/Rear Blower and Zone Control
ACTUATOR CALIBRATION
Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the
actuators, HVAC control module and its linkages. In vehicle calibration can be entered from the
control's front panel. If the REAR WIPE and INTERMITTENT LED's flash simultaneously when
Ignition is cycled ON, the actuators have not been calibrated or during the previous calibration a
failure occurred. Diagnostics will always occur during Calibration Diagnostic and Cooldown test.
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Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
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DIAGNOSTICS
During the Actuator calibration, diagnostics are performed on the actuators and evaporator
temperature Fin Sensor. Once diagnostics are completed the REAR WIPER and INTERMITTENT
LED's will flash to indicate either a successful calibration or the appropriate fail code(s). At this time
manual testing of the Blend, Mode and Driver (if equipped) potentiometers can be performed. If a
failure is detected during Diagnostics a fault will be set in the control. When Ignition is cycled OFF
and then ON or Diagnostics is aborted, the REAR WIPER and INTERMITTENT LED's will flash
simultaneously showing that a failure has occurred. The control will not indicate the fail code, but
only that a failure had occurred during the last diagnostics test. The only way to clear the failure
codes is repeat the Calibration Diagnostic and Cooldown test, after all repairs are completed.
COOLDOWN TEST
This test has been designed for performance testing of the A/C system at the manufacturing
facility. If the IWAC control module is replaced, the Cooldown test will occur during Calibration test.
Cooldown will not occur on Heater Only units. During the Cooldown test the control will monitor the
temperature of the Fin Sensor. The A/C system must be able to bring the evaporator temperature
down a predetermined minimum amount in less than 2 minutes.
CALIBRATION / COOLDOWN LED DISPLAY CODES
Calibration / Cooldown LED Display Codes
See chart for definition of the flashing LED's noted before ignition cycled off. If no problems are
found, the control functions normally.
NOTE: Calibration is run automatically whenever the control head detects a "new" VIN number.
Calibration may be initiated manually by pressing and holding WASH and REAR WIPER buttons
for 5 seconds.
COOLDOWN TEST ENTRY
To Initiate Test: Set Blower motor ON HIGH
- Open all A/C outlets
- Depress A/C and WASH buttons simultaneously for 5 seconds (until all LED's light)
Results: All LED's will turn on for 5 seconds
- Cooldown test is running if A/C and RECIRC are alternately flashing
- Acceptable result is when LED flashing stops
- Calibration Diagnostics and Cooldown must be run separately
CALIBRATION DIAGNOSTICS AND COOLDOWN ABORT
Test can be aborted by doing one of the following:
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and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 5341
- Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons.
- Cycling Ignition OFF and then ON. Control will automatically abort after 15 minutes from the time
Calibration Diagnostics and Cooldown was entered.
The HVAC control module will return to normal operation or may indicate unsuccessful Calibration
Diagnostics or Cooldown test by LED's flashing simultaneously.
COOLDOWN TEST FAILURE
Determine if the refrigerant system is operating correctly: Check the outlet air temperature
- Feel the compressor suction plumbing, is it hot?
1. If not OK, go to Step 2. If OK, repeat the Calibration Diagnostic and Cooldown test. 2. If system
does not seem to be operating correctly, perform diagnostics for poor performance:
- Low refrigerant charge
- No charge
- Compressor not operating
Verify that the test was done with the evaporator at room temperature. The test consists of starting
the compressor and measuring the time it takes for the evaporator temperature to fall 7 °C (20 °F).
If the compressor has been running, the evaporator is cold already and will not be capable of falling
7 °C (20 °F). If the test was run with a cold evaporator, turn A/C off and turn the blower motor
switch to high position for 3 to 5 minutes till the evaporator is to room temperature. Then repeat the
Calibration Diagnostic and Cooldown test.
If refrigerant system is performing properly and the system will not pass test. Repeat the
Calibration Diagnostic and Cooldown test to determine if the evaporator temperature FIN sensor
has developed an open or a short circuit. If the HVAC control module still passes Calibration test,
verify Cooldown test manually with a pocket thermometer. The outlet air temperature must drop at
least 7 °C (20 °F) within two minutes. If the vehicle passes with the manual thermometer, use the
DRB Ill® viewing the evaporator probe temperature readout, and repeat the Cooldown test. Ensure
the evaporator is at room temperature before starting test. Check if evaporator probe will drop the
temperature 7 °C (20 °F) in two minutes. If the Evaporator Probe is found to be faulty, check that
the sensor is positioned in the evaporator fins properly. If not, correct and repeat test. If OK,
replace the evaporator probe.
Once the repairs are completed, repeat the Calibration Diagnostic and Cooldown test. Repeating
the test is necessary to clear the DTC's.
EEPROM DATA
Calibration Diagnostics, Cooldown Status and evaporator temperature Fin Sensor values are
stored in an EEPROM memory internal to the control. The microcomputer within the HVAC control
module uses this information: To determine if Cooldown needs to run
- For proper position of the Heater-A/C unit assembly doors
ACTUATOR CALIBRATION AND DIAGNOSTICS
NOTE: Do not run actuators unless they are properly mounted on the HVAC control module.
Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and
INTERMITTENT LED's will flash alternately during the test. The control will cycle the Blend
actuator(s) to the Heat stop first then back to Cold. After the Blend actuator(s) have been calibrated
the Mode actuator will be cycled to Defrost and then to Panel. Successful calibration is defined as
actuator travel falling within their minimum and maximum limits.
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and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 5342
Control Assembly: Testing and Inspection HVAC Control Diagnostic Conditions
After calibration, Rear Wiper LED flashing once, Intermittent LED not flashing.
The system has passed calibration. Press the Rear Wiper button to exit calibration.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing once. The mode actuator
did not reach defrost position.
1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery
voltage. Move the HVAC control from the defrost to
panel position, and check Pin 6 voltage it should change from 0.5 - 1 volts to 3.5 - 4.5 volts. If
voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted
circuit and repair as necessary.
2. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 3. If not OK, repair as
necessary
3. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace
actuator. 4. Once repairs are completed repeat the Calibration Diagnostic and Cooldown test.
Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing twice. The mode
actuator did not reach panel position.
1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery
voltage. Move the HVAC control from panel to defrost
position , and check Pin 6 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1 volts. If voltage is
OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted circuit and
repair as necessary.
2. Remove actuator, and check if the gear pins are in the correct cam track or binding. If OK, go to
Step 3. If not OK, repair as necessary. 3. Check for binding door, if door is binding repair as
necessary. If gears and door are OK, replace actuator. 4. Once repairs are completed repeat the
Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing three times. The main
temperature actuator/passenger temperature actuator on a zone system did not reach cold stop.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the
temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC
control from the cold
to hot position, and check Pin 5 voltage it should change from 0.5 - 4 volts to 3.5 - 4.5 volts. If
voltage is OK, go to Step 3.If not OK, check for loose or corroded connector, open or shorted circuit
and repair as necessary.
3. Remove actuator, and check if gear pins are in the correct cam track or binding. If OK, go to
Step 4. If not OK, repair as necessary. 4. Check for binding door, if door is binding repair as
necessary. If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the
Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing four times. The main
temperature actuator, passenger temperature actuator on a zone system did not reach hot stop.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the
temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC
control from hot to
cold position and check Pin 5 voltage it should change from 3.5 - 4.5 volts 0.5 - 1.5 volts. If voltage
is OK, go to Step 3.If not OK, check for loose or corroded connector, open or shorted circuit and
repair as necessary.
3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 4.If not OK, repair as
necessary.
4. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace
actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cooldown test.
Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing live times. The
evaporator probe is open.
1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If
OK, go to Step 2. If not OK, if greater than 4.75
volts check for loose or corroded connector, open circuit and repair as necessary.
2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3.If not OK, check for loose
or corroded connector, open or shorted circuit
and repair as necessary
3. If ground and power circuit are OK, replace Evaporator Probe. 4. Once repairs are completed,
press the intermittent button about 5 seconds until all LED's light to remove fault code from
memory. Then repeat the
Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing six times. The
evaporator probe is shorted.
1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If
OK, go to Step 2. If less than 0.1 volts, check for
loose or corroded connector, open or shorted circuit and repair as necessary.
2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3.If not OK, check for
shorted circuit and repair as necessary. 3. If ground and power circuit are OK, replace Evaporator
Probe. 4. Once repairs are completed, press the intermittent button about 5 seconds until all LED's
light to remove fault code from memory. Then repeat the
Calibration Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermillent LED flashing seven times. The Driver's
temperature actuator on a zone system did not reach cold stop.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the
temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC
control from cold to
the hot position, check Pin 4 voltage it should change from 0.5 - 1.5 volts 3.5 - 4.5 volts. If voltage
is OK, go to Step 3. If not OK, check for loose
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
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and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 5343
or corroded connector, open or shorted circuit and repair as necessary.
3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 4. If not OK, repair as
necessary.
4. Check for binding doors, if door are binding repair as necessary If gears and door are OK,
replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cooldown
test. Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing eight times. The Driver's
temperature actuator on a zone system did not reach hot stop.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the
temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC
control from hot to
cold position, Pin 4 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1.5 volts. If voltage is OK,
go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as
necessary.
3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 4. If not OK, repair as
necessary
4. Check for binding door, if door is binding repair as necessary If gears and door are OK, replace
actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cooldown test.
Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing nine times. The HVAC
control module, has a internal failure.
1. Replace the HVAC control module. 2. Once repairs are completed repeat the Calibration
Diagnostic and Cooldown test. Repeating the test is necessary to clear the fault codes.
After calibration and testing the A/C and RECIRC LED flashing simultaneously. Failed Cooldown
test.
1. Determine if the refrigerant system is operating correctly:
- Check the outlet air temperature
- Feel the compressor suction plumbing, is it hot?
1. If not OK, go to Step 2.If OK, repeat the Calibration Diagnostic and Cooldown test. 2. If system
does not seem to be operating correctly, perform diagnostics for poor performance:
- Low refrigerant charge
- No charge
- Compressor not operating
Verify that the test was done with the evaporator at room temperature. The test consists of starting
the compressor and measuring the time it takes for the evaporator temperature to fall 7°C (20°F). If
the compressor has been running, the evaporator is cold already and will not be capable of falling
7° C (20° F). If the test was run with a cold evaporator, turn A/C off and turn the blower motor
switch to high position for 3 to 5 minutes till the evaporator is to room temperature. Then repeat the
Calibration Diagnostic and Cooldown test.
If refrigerant system is performing properly and the system will not pass test. Repeat the
Calibration Diagnostic and Cooldown test to determine if the evaporator temperature FIN sensor
has developed an open or a short circuit. If the HVAC control module still passes Calibration test,
verify Cooldown test manually with a pocket thermometer. The outlet air temperature must drop at
least 7° C (20° F) within two minutes. If the vehicle passes with the manual thermometer, take
HVAC control to level 4 (evaporator probe temperature readout) and repeat the Cooldown test.
Ensure the evaporator is at room temperature before starting test. Check if evaporator probe will
drop the temperature 7° C (20° F) in two minutes. If the Evaporator Probe is found to be faulty
check that the sensor is positioned in the evaporator fins properly If not, correct and repeat test. If
OK, replace the evaporator probe.
Once the repairs are completed, repeat the Calibration Diagnostic and Cooldown test. Repeating
the test is necessary to clear the fault codes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement
Control Assembly: Service and Repair Heater-A/C Control Lamp Replacement
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable.
HVAC Control Lamps
2. Remove radio bezel and HVAC Control. 3. Remove rear cover from HVAC control. 4. Rotate
bulb socket counterclockwise one quarter turn. 5. Pull bulb socket from HVAC.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement > Page 5346
Control Assembly: Service and Repair Radio Bezel and HVAC Control Replacement
REMOVAL
1. Remove convenience bin - cup holder. Refer to Body and Frame/Interior Trim/Drink
Holder/Convenience Bin - Cup Holder Replacement. 2. Insert the trim stick (special tool #C-4755)
between access cover and radio bezel, above convenience bin - cup holder.
Convenience Bin Access Cover
3. Carefully pry the access cover from the instrument panel. 4. Separate the access cover from the
vehicle. 5. Remove convenience bin - cup holder track. Refer to Convenience Bin - Cup Holder
Track Replacement.
Radio Bezel And HVAC Control
6. Remove the attaching screws holding bottom of the bezel to instrument panel. 7. Remove the
attaching screws holding top of the bezel to the instrument panel. 8. Remove the bezel from the
instrument panel. 9. Disconnect the wire connector from back of the rear blower switch, if
equipped.
10. Disconnect the wire connector from the back of the HVAC Control. 11. Remove the bezel.
INSTALLATION
1. Hold the radio bezel up and connect the wire connector into the back of the HVAC control. 2.
Connect the wire connector into back of the rear blower switch, if equipped. 3. Place the radio
bezel in position on the instrument panel. 4. Install screws to hold the top of radio bezel to
instrument panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement > Page 5347
5. Install screws to the hold bottom of the radio bezel to the instrument panel. 6. Install the access
cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement > Page 5348
Control Assembly: Service and Repair Rear Heater-A/C Switch Lamp Replacement
REMOVAL
1. Remove rear heater-A/C control from trim panel. 2. On the back of control opposite from the wire
connectors, locate the bulb socket lug. 3. Rotate the socket counterclockwise and pull the socket
from the control.
INSTALLATION
For installation, reverse the above procedures. Refer to Lamps for bulb usage.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement > Page 5349
Control Assembly: Service and Repair Sticking HVAC Control Module Push Buttons
Sticking HVAC Control Module Push Buttons
To service HVAC control module push buttons that are sticking, spray between the buttons with
Mopar MP-50. The MP-50 is a all purpose lubricant for mechanical and electrical uses. After
spraying around the push buttons wipe any excess off the radio bezel and HVAC control module
push buttons. Operate the buttons to ensure that they are operating freely.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications
Evaporator Core: Specifications
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG
(polyalkalene glycol).
Front A/C
- Compressor .......................................................................................................................................
................................................... 150 ml (5.0 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
Dual A/C
- Compressor .......................................................................................................................................
................................................... 220 ml (7.4 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
- Rear Evaporator ................................................................................................................................
..................................................... 60 ml (2.0 oz)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core
Evaporator Core: Service and Repair Front Evaporator Core
REMOVAL
1. Set parking brake. 2. Disconnect battery negative cable.
A/C Service Ports
3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 4. Remove Wiper
module. 5. Pinch off rear heater lines if equipped.
Heater Hoses
6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 5355
Expansion Valve Plate
7. Remove suction and liquid lines at the expansion valve. 8. Remove the Instrument Panel
Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and
Repair".
See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
9. Remove heater ducts.
10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the
tunnel.
HVAC Bolt Up
11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel. 12
Disconnect the HVAC housing wiring harness.
13 Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down.
Pull it rearward to remove it from vehicle.
Evaporator Core Removal
1. Place HVAC unit assembly on workbench.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 5356
Distribution Housing
2. Remove distribution housing mounting screws.
Blower Motor Cover
3. Remove blower motor cover.
Blower Motor Grommet
4. Remove blower motor wiring grommet and feed wiring through blower housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 5357
Blower Motor Screws
Blower Motor
5. Remove blower motor screws. Remove blower motor from housing.
Recirculation Door Cover
6. Remove recirculation door cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 5358
Recirculation Door
7. Remove recirculation door.
HVAC Cover
8. Remove screws around the perimeter of the upper HVAC housing.
CAUTION: Do not damage the insulation barrier surrounding the evaporator.
Evaporator
9. Carefully pull up on evaporator and remove from housing.
10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of
the same amount (ND8 PAG) to the new
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 5359
evaporator before installing.
Note: For reassembly of the evaporator housing, reverse the above procedures.
- Perform the HVAC control Calibration Diagnostic and Cool-down test. Refer to: "Testing and
Inspection" See: Testing and Inspection
INSTALLATION
1. For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing
inlets 2. Evacuate and recharge the A/C system. 3. Perform HVAC control Calibration Diagnostic
and Cool-down test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 5360
Evaporator Core: Service and Repair Rear Evaporator Core
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE
FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF
ALL PRESSURE.
1. Remove right quarter trim panel and D-pillar trim. Refer to: "Body and Frame : Interior Trim :
Trim Panel : Service and Repair" See: Body
and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair
2. Remove fan A/C distribution duct. 3. Remove rear A/C unit. 4. Remove blower scroll.
Evaporator Cover
5. Remove evaporator cover.
Expansion Valve
6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 5361
Evaporator Removal
7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing
surfaces with the plumbing extension tube pilots. 8. Remove and discard the 0-rings between the
plumbing extension and the expansion valve. 9. Cover the plumbing extension sealing surface to
prevent contamination.
10. Bring evaporator and expansion valve to a clean work space. 11. Remove two 1/4-20 Torx
Head screws. 12. Remove expansion valve. 13. Measure and record the amount of residual oil
from the removed evaporator.
INSTALLATION
1. Replace the O-rings. 2. Hold expansion valve against evaporator sealing plate (do not scratch
the sealing surface). Install two screws and tighten to 11 ± 3 Nm (100 ± 30
inch pounds) torque.
CAUTION: Do not damage the evaporator insulation liner during installation.
3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the
sealing surfaces with the plumbing extension tube
pilots.
4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of
clean refrigerant oil) back into the system. 5. Carefully align the expansion valve onto the pilot
tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the
plumbing plate into the unit sealing plate. Tighten bolts to 23 ± 3 Nm (200 ± 30 inch pounds)
torque.
6. Install evaporator cover and blower scroll. 7. Install quarter trim panel, evacuate/charge system,
and perform the performance test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Description
and Operation
Evaporator Drain Tube: Description and Operation
SYSTEM OPERATION
Condensate Drain Condensation from the evaporator housing is drained through the dash panel
and on to the ground. This drain must be kept open to prevent water from collecting in the bottom
of the housing.
If the drain is blocked condensate cannot drain, causing water to back up and spill into the
passenger compartment. It is normal to see condensate drainage below the vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Description and Operation
Evaporator Temperature Sensor / Switch: Description and Operation
SYSTEM OPERATION
Evaporator Probe The Evaporator probe is located on the HVAC. The probe prevents evaporator
freeze-up by signaling the Powertrain Control Module to cycle the compressor ON and OFF. The
probe monitors the temperature of the refrigerant after expansion.
The evaporator probe is inserted into the evaporator between the coils. The probe is a sealed unit
and cannot be adjusted or repaired. It must be replaced if found defective.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics
Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Temperature
Diagnostics
The evaporator probe can be tested by using the INTERMITTENT LED to display the actual
temperature the sensor is reading. The HVAC control module can only display temperatures from 1
to 99 degrees. To read the temperature, perform the following:
- Set Blower motor to any speed other than OFF
- Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared. To clear
the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then,
press and hold the intermittent wipe button for 5 seconds.
- Run Diagnostics (Depress REAR WIPER and REAR WASH)
- When Diagnostics is complete, Cycle to Level 4.
Display Sequence is as follows:
- REAR WIPER LED will display the Level
- INTERMITTENT LED will display ten's digit
- Short Pause
- INTERMITTENT LED will display the one 5 digit.
The HVAC control module will continue to cycle the Level and then Temperature until the level is
changed or Calibration Diagnostics and Cooldown test is exited.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 5370
Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Test
Evaporator Probe: Resistance Vs. Temperature Chart
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 5371
Resistance Measurement Table
The evaporator probe is located in the unit housing and placed in the evaporator fins. The probe
prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when
evaporator temperature drops below freeze point. It cycles ON when the evaporator temperature
rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The
tube is inserted between the evaporator fins in the heater-A/C unit housing.
A malfunctioning evaporator probe may show symptoms such as:
- Ice blocking the airflow, or frost exiting out of the outlets and vents
- No air conditioning operation
- No power to the compressor clutch during A/C selection
The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) during testing.
1. Place the vehicle in a location out of direct sunlight and allow the vehicle to come to ambient
temperature (the engine can remain warm). 2. With the engine OFF, lower the windows, and turn
on the interior blower (with the system in Fresh Air mode). 3. Place a thermometer in one of the
Instrument Panel outlets, and a second one in the intake duct (plenum area by the windshield
wipers). 4. Allow the blower to run until both temperatures readings are within 2° F of one another
and constant. 5. Remove the electrical connector from the evaporator probe and measure the
resistance of the probe with a multimeter.
6. Consult the temperature/resistance chart and table to determine whether the resistance is within
specification.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page 5372
If the measurements fall outside the specifications, replace the evaporator probe.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Testing and Inspection > Page 5373
Evaporator Temperature Sensor / Switch: Service and Repair
REMOVAL
1. Remove the glove box. Refer to Instrument Panel and Systems.
Evaporator Probe Connector
2. Disconnect the evaporator probe connector.
Evaporator Probe Grommet
3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing.
Evaporator Probe
4. Remove evaporator probe from evaporator.
INSTALLATION
For installation, reverse the above procedures. Three holes are provided in evaporator for probe
location. When reinstalling probe, use a different hole than original one. If a new evaporator is
installed, insert the probe in the uppermost hole provided.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Testing and
Inspection
Expansion Valve: Testing and Inspection
NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
Tests
NOTE: Expansion valve tests should be performed after compressor tests.
Review Safety Precautions and Warnings. The work area and vehicle temperature must be 21° C
to 27° C (70° F to 85° F). To test the expansion valve:
NOTE: Liquid CO2 is required to test the expansion valve. It is available from most welding supply
facilities. CO2 is also available from companies which service and sell fire extinguishers.
1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify
the refrigerant charge level. 2. Close all doors, windows and vents to the passenger compartment.
3. Set heater A/C control to A/C, full heat, FLOOR, and high blower. 4. Start the engine and allow
to idle (1000 rpm).After the engine has reached running temperature, allow the passenger
compartment to heat up. This
will create the need for maximum refrigerant flow into the evaporator.
5. If the refrigerant charge is sufficient, discharge (high pressure) gauge should read 965 to 1655
kPa (140 to 240 psi). Suction (low pressure) gauge
should read 140 kPa to 207 kPa (20 psi to 30 psig). If system cannot achieve proper pressure
readings, replace the expansion valve. If pressure is correct, proceed with test.
WARNING: PROTECT SKIN AND EYES FROM CONTACTING CO2 PERSONAL INJURY CAN
RESULT.
6. If suction side low pressure is within specified range, freeze the expansion valve control head for
30 seconds. Use a super cold substance (liquid
CO2). Do not spray R-134a or R-12 Refrigerant on the expansion valve for this test. Suction side
low pressure should drop by 10 psi. If not, replace expansion valve.
7. Allow expansion valve to thaw. The low pressure gauge reading should stabilize at 140 kPa to
240 kPa (20 psi to 30 psig). If not, replace
expansion valve.
8. When expansion valve test is complete, test A/C overall performance. Remove all test
equipment before returning vehicle to use.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Expansion Valve Removal and Installation
Expansion Valve: Service and Repair Expansion Valve Removal and Installation
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
REMOVAL
1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the
accessory drive belt. 4. Remove upper generator bracket. 5. Disconnect generator field wire
connector. 6. Push generator forward. 7. Remove ground wire at dash panel.
A/C Refrigerant Line Plate
8. Remove the nut retaining the refrigerant line sealing plate to the expansion valve.
Expansion Valve Stud And Mounting Screws
9. Remove the stud from the expansion valve.
10. Carefully pull the refrigerant line sealing plate assembly from expansion valve towards the front
of the vehicle. Use care not to scratch the
expansion valve sealing surfaces with pilot tubes.
11. Cover the openings to prevent contamination. 12. Remove two screws securing the expansion
valve to the evaporator sealing plate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Expansion Valve Removal and Installation > Page 5379
Expansion Valve Removal
13. Carefully remove expansion valve. 14. Remove the old O-rings.
INSTALLATION
1. Ensure old O-rings are removed. Install new O-rings on the refrigerant lines and evaporator
sealing plate. 2. Hand-start the stud into the expansion valve and torque to 7 - 11 Nm (64 - 96 in.
lbs.). 3. Carefully install the expansion valve to the sealing plate. Install the two screws and tighten
8 to 14 Nm (70 to 130 in. lbs.) torque. 4. Carefully install the refrigerant lines and sealing plate to
the expansion valve. Install the nut and tighten 20 to 26 Nm (170 to 230 in. lbs.) torque. 5. Install
the ground wire at dash panel. 6. Pull generator back into the proper position for bracket mounting.
7. Install generator field wire connector. 8. Install the upper generator bracket. 9. Install accessory
drive belt.
10. Evacuate and recharge system. 11. After expansion valve is installed, the system is charged,
and leaks have checked repeat the A/C performance check.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Expansion Valve Removal and Installation > Page 5380
Expansion Valve: Service and Repair Evaporator Core and Expansion Valve Replacement
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE
FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF
ALL PRESSURE.
1. Remove right quarter trim panel and D-pillar trim. 2. Remove fan A/C distribution duct. 3.
Remove rear A/C unit. 4. Remove blower scroll.
Evaporator Cover
5. Remove evaporator cover.
Expansion Valve
6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Expansion Valve Removal and Installation > Page 5381
Evaporator Removal
7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing
surfaces with the plumbing extension tube pilots. 8. Remove and discard the 0-rings between the
plumbing extension and the expansion valve. 9. Cover the plumbing extension sealing surface to
prevent contamination.
10. Bring evaporator and expansion valve to a clean work space. 11. Remove two 1/4-20 Torx
Head screws. 12. Remove expansion valve. 13. Measure and record the amount of residual oil
from the removed evaporator.
INSTALLATION
1. Replace the O-rings. 2. Hold expansion valve against evaporator sealing plate (do not scratch
the sealing surface). Install two screws and tighten to 11 ± 3 Nm (100 ± 30
inch pounds) torque.
CAUTION: Do not damage the evaporator insulation liner during installation.
3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the
sealing surfaces with the plumbing extension tube
pilots.
4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of
clean refrigerant oil) back into the system. 5. Carefully align the expansion valve onto the pilot
tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the
plumbing plate into the unit sealing plate. Tighten bolts to 23 ± 3 Nm (200 ± 30 inch pounds)
torque.
6. Install evaporator cover and blower scroll. 7. Install quarter trim panel, evacuate/charge system,
and perform the performance test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Front Heater Core
Heater Core: Service and Repair Front Heater Core
REMOVAL
1. Drain coolant system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and
Repair" See: Engine, Cooling and
Exhaust/Cooling System/Service and Repair
2. Remove left side lower column cover. 3. Remove steering column assembly. Refer to: "Steering
and Suspension : Steering : Steering Column : Service and Repair" See: Steering and
Suspension/Steering/Steering Column/Service and Repair
ABS Module
4. Remove ABS module, bracket and wiring.
Interconnect And Bracket
5. Remove I/P to body harness interconnect and bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Front Heater Core > Page 5386
Lower Silencer Boot
6. Remove lower silencer boot at base of steering shaft. 7. Pinch off heater lines under the hood.
Heater Core Plate And Tubes
8. Remove heater core cover. Insert a small amount of towels under the heater core tubes.
Remove heater core plate and tubes.
Depress Clips
9. Depress heater core retaining clips.
Accelerator Pedal
10. Pull up on accelerator pedal and slide heater core past.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Front Heater Core > Page 5387
Brake Pedal
11. Depress brake pedal and remove heater core from HVAC housing.
INSTALLATION
For installation, reverse the above procedures. Install screws to retain heater core in housing.
Replace heater core tube inlet O-rings. Tighten heater core tube retaining plate to 3 ± 1 NM (27 ± 9
in. lbs.) torque.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Front Heater Core > Page 5388
Heater Core: Service and Repair Rear Heater Core
REMOVAL
1. Remove the lower right quarter trim panel. Refer to: "Body and Frame : Interior Trim : Trim Panel
: Service and Repair" See: Body and
Frame/Interior Moulding / Trim/Trim Panel/Service and Repair
Heater Core Lines
2. Isolate and disconnect lines from heater core. 3. Remove heater core retaining screws. 4.
Carefully pull the heater core and tubes up and straight out of the unit.
INSTALLATION
Filling Heater Core
For installation, reverse the above procedures. Prefill the heater core. Test for leaks and overall
performance.
NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the
vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater
core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat
opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled
completely, the following procedure can be used:
- Vehicle at room temperature.
- Engine is brought up to operating temperature.
- Front unit is OFF, temperature slides are at full HEAT position.
- Engine is at idle.
- With rear blower motor ON HIGH
- Discharge air temperature measured at the dual register located on the C-pillar base, is between
57° C to 62° C (135° and 145° F).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair
Heater Hose: Service and Repair
REMOVAL
NOTE: Review Safety Precautions and Warnings before proceeding with this operation.
1. Drain engine cooling system.
Upper Heater Hose
Lower Heater Hose
2. Loosen clamps at each end of heater hose to be removed.
CAUTION: When removing hoses from heater core inlet or outlet nipples, do not use excessive
force. Heater core may become damaged and leak engine coolant.
3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the
hose will not come off, slice the hose at the
connector nipple and peel off heater hose. This method will require heater hose replacement.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Specifications
High Pressure Safety Valve HVAC: Specifications
The valve is calibrated to vent at a pressure of 3450 to 4140 kPa (500 to 600 psi)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Specifications > Page 5395
High Pressure Safety Valve HVAC: Description and Operation
SYSTEM OPERATION
Compressor High-Pressure Relief Valve The High Pressure Relief Valve prevents damage to the
air conditioning system if excessive pressure develops. Excessive pressure can be caused by
condenser air flow blockage, refrigerant overcharge, or air and moisture in the system.
The high pressure relief valve vents only a small amount of refrigerant necessary to reduce system
pressure and then reseats itself. The majority of the refrigerant is conserved in the system. The
valve is calibrated to vent at a pressure of 3450 to 4140 kPa (500 to 600 psi). If a valve has vented
a small amount of refrigerant, it does not necessarily mean the valve is defective.
The High Pressure Relief Valve is located on the compressor manifold at the discharge passage.
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > A/C Suction/Discharge Line - Service
Hose/Line HVAC: Technical Service Bulletins A/C Suction/Discharge Line - Service
NUMBER: 24-14-99
GROUP: Heating & A/C
DATE: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-11-98 REV. A, DATED
JULY. 24, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Suction And/Or Discharge Line Service
MODELS:
1996 - **2000** (NS) Town & Country/Caravan/Voyager 1996 - **2000** (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
DISCUSSION: It an A/C suction and/or discharge line requires replacement due to cracking at or
near the compressor, inspect the three (3) A/C compressor mounting bolts and be sure they are
torqued to 40 ft. lbs. (54 Nm).
The root cause of A/C suction and/or discharge line cracking at or near the compressor may be
related to the compressor being improperly secured to the engine. Excessive vibration may result if
the compressor attaching bolts are not properly torqued. This vibration will eventually crack the
aluminum tubing of the A/C lines and/or compressor mounting ears.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement
Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement
REMOVAL
1. Recover A/C system refrigerant.
Compressor Discharge Line
2. Remove discharge line mounting nut at compressor.
Condenser Discharge Line
3. Remove discharge line at the top fitting on the condenser.
INSTALLATION
1. For installation , reverse the above procedures. Replace all O-rings. Torque discharge line at
condenser bolt to 180 in. lbs. ± 10. 2. Evacuate and recharge A/C system. 3. Perform the HVAC
Control Calibration Diagnostic and Cooldown test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 5402
Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement
REMOVAL
1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the
accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel.
A/C Refrigerant Line Plate
6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve.
Expansion Valve Stud And Mounting Screws
7. Remove the stud from the expansion valve. 8. Remove liquid line from expansion valve. 9.
Cover the openings to prevent contamination.
10. Disconnect wire connector at pressure transducer. 11. Remove liquid line mounting bracket at
right frame rail. 12. Using access slot between radiator crossmember and grille, loosen liquid line
mounting plate at filter-drier. Remove liquid line from filter-drier. It
may be necessary to bend liquid line in half to remove line. The replacement line is a two-piece
assembly.
13. Remove the old O-rings.
INSTALLATION
For installation, reverse the above procedures.
- Install the stud to the evaporator sealing plate and tighten 7 to 11 Nm (64 to 96 in. lbs.) torque.
- Install new O-rings.
- Install two-piece line in place of original part.
- Assemble line halves after it is installed on vehicle.
- Evacuate and recharge A/C system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 5403
Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement
REMOVAL
1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the
accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel.
A/C Refrigerant Line Plate
6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve.
Expansion Valve Stud And Mounting Screws
7. Remove the stud from the expansion valve. 8. Remove suction line from expansion valve.
Suction Line At Compressor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 5404
9. Remove suction line mounting nut at compressor.
10. Remove suction line mounting bracket. 11. Remove suction line.
INSTALLATION
For installation, reverse the above procedures.
- Install the stud to the evaporator sealing plate and tighten 7 to 11 Nm (64 to 96 in. lbs.) torque.
- Install new O-rings.
- Install two-piece line in place of original part.
- Assemble line halves after it is installed on vehicle.
- Evacuate and recharge A/C system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 5405
Hose/Line HVAC: Service and Repair Refrigerant Line Replacement
Rear Air Conditioning Lines
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
REMOVAL
1. Hoist vehicle
Front Lines Connected To Rear Lines
2. Remove compression fittings to the suction and liquid lines located on the right, outboard side of
the underbody, rearward of the front
crossmember.
Rear A/C Block Connection
3. Remove (1) bolt securing A/C lines to block located on the right, outboard side of the underbody,
rearward of the rear wheel and tire.
Rear Heater And A/C Lines
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 5406
4. Remove (3) straps securing underbody lines. 5. Separate and remove A/C lines from vehicle.
INSTALLATION
1. Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved
wax-free refrigerant oil. Then, reverse the above
procedures.
2. Evacuate and recharge system.
Rear Heater Lines
REMOVAL
NOTE: Review Safety Precautions and Warnings before proceeding with this operation.
1. Partially drain engine cooling system.
Front Lines Connected To Rear Lines
2. Loosen clamp at the front end of the hose located at the right, outboard side of the underbody,
rearward of the front crossmember. 3. Carefully rotate hose back and forth while tugging slightly
away from connector nipple. If the hose will not come off, slice the hose at the
connector nipple and peel off heater hose. This method will require heater hose replacement.
CAUTION: When removing hoses from outlet nipples, do not use excessive force. Outlet nipples
may become damaged and leak engine coolant.
Rear Heater Hose Quick Connects
4. Compress insert in rear heater hose quick connection and pull downward on hose.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 5407
Rear Heater And A/C Lines
5. Remove (3) straps securing underbody lines. 6. Separate and remove rear heater lines from
vehicle.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly
Housing Assembly HVAC: Service and Repair Evaporator Housing Disassembly and Assembly
NOTE: In order to service the air flow control box you must first remove the evaporator core. Refer
to: "Evaporator Core : Service and Repair" See: Evaporator Core/Service and Repair
DISASSEMBLY
1. Place HVAC unit assembly on workbench.
Distribution Housing
2. Remove distribution housing mounting screws.
Blower Motor Cover
3. Remove blower motor cover.
Blower Motor Grommet
4. Remove blower motor wiring grommet and feed wiring through blower housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5412
Blower Motor Screws
Blower Motor
5. Remove blower motor screws. Remove blower motor from housing.
Recirculation Door Cover
6. Remove recirculation door cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5413
Recirculation Door
7. Remove Recirc door.
HVAC Cover
8. Remove screws around the pen meter of the upper HVAC housing.
CAUTION: Do not damage the insulation barrier surrounding the evaporator.
Evaporator
9. Carefully pull up on evaporator and remove from housing.
10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of
the same amount (ND8 PAG) to the new
evaporator before installing. Use SP 10 PAG oil for 2.5L diesel and 2.0L gasoline engine vehicles.
ASSEMBLY
1. For reassembly of the evaporator housing, reverse the above procedures. 2. Perform the HVAC
control Calibration Diagnostic and Cool-down test. See: Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5414
Housing Assembly HVAC: Service and Repair Heater-A/C Housing Disassembly and Assembly
NOTE: In order to service the air flow control box you must first remove the evaporator core. Refer
to: "Evaporator Core : Service and Repair" See: Evaporator Core/Service and Repair
Distribution Housing
1. Place distribution housing on workbench.
Heater Core Cover
2. Remove heater core cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5415
Heater Core Tube Plate
Plate Removal
3. Remove heater core tube plate.
Heater Core Tube Removal
4. Remove heater core tubes. 5. Depress heater core retaining clips at housing. When reinstalling
core use screws to fasten the heater core to the housing. 6. Slide heater core out of the housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5416
Drivers Zone Actuator
7. Remove driver's zone actuator from distribution housing.
Passenger Zone Actuator
8. Remove passenger zone actuator from distribution housing.
Distribution Housing
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5417
Blend Air Door Drive Gear
9. Using a long thin flat blade tool, insert tool through blend-air opening on top of distribution
housing. Depress clip retaining the driver's blend-air
door drive gear. Pull out on gear and remove from the housing.
10. Remove mode door motor.
Panel Door Gear
11. Remove Panel door actuator gear.
Defrost Door Gear
12. Remove defrost door actuator gear.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5418
Cam Wheel
13. Remove cam wheel.
Heat Door Gear
14. Remove heat door actuator gear.
Distribution Housing
15. Remove distribution housing lower cover screws.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5419
Distribution Housing Half Screws
16. Remove distribution housing half screws.
Front Cover
Zone Control Doors
17. Remove distribution housing front cover. 18. Remove weather-strip at fresh-air vent.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5420
Distribution Housing Halves
19. Separate housing halves.
Defrost Door
20. Pull up on separator plate and remove defrost door.
Panel Door
21. Remove upper half Panel door.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5421
Floor Door
22. Remove upper half of Floor door.
Blend Air Door
23. Remove upper half of the blend-air door (slide off of shaft).
Separator Plate
24. Remove separator plate from distribution housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5422
Lower Blend Air Door
25. Remove lower half of the blend-air door.
Lower Panel Door
26. Remove lower half of the Panel door.
Lower Floor Door
27. Remove lower half of the Floor door.
ASSEMBLY
For reassembly of the distribution housing, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5423
NOTE: To reassemble the distribution housing actuator gears an assembly procedure of the gears
and cam is necessary.
ACTUATOR GEARS ALIGNMENT PROCEDURE
1. Install lower FLOOR door actuator gear to housing. Match master spline of FLOOR door
actuator gear to master spline on door. 2. Install cam wheel. Align cam wheel track to FLOOR door
actuator gear. 3. Align cam wheel slot with the post on the distribution housing marked "1". 4.
Install PANEL door actuator gear. Align master spline of PANEL door actuator gear to master
spline on PANEL door. Position actuator gear
within cam wheel track.
5. Install DEFROST door actuator gear to housing. Match master spline of DEFROST door
actuator to master spline on DEFROST door. Position
actuator gear within cam wheel track.
6. Reinstall housing in vehicle. 7. Perform the HVAC control Calibration Diagnostic and Cool-down
test. Refer to: "Testing and Inspection : Procedures" See: Testing and
Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5424
Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING, THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING.
1. Set parking brake. 2. Disconnect battery negative cable.
A/C Service Ports
3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Refer to: "Testing
and Inspection" See: Testing and Inspection 4. Remove wiper module. Refer to Windshield Wipers
and Washers. See: Wiper and Washer Systems/Service and Repair 5. Pinch off rear heater lines if
equipped.
Heater Hoses
6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines. Refer to:
"Engine, Cooling and Exhaust : Cooling System :
Service and Repair" See: Engine, Cooling and Exhaust/Cooling System/Service and Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5425
Expansion Valve Plate
7. Remove suction and liquid lines at the expansion valve. 8. Remove the Instrument Panel
Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and
Repair".
See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
9. Remove heater ducts.
10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the
tunnel.
HVAC Bolt-up
11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel. 12.
Disconnect the HVAC housing wiring harness. 13. Pull the entire unit rearward until the studs on
the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle.
INSTALLATION
1. For installation of the assembly, reverse the above procedures. Install new 0-rings on plumbing
inlets 2. Evacuate and recharge the A/C system. 3. Perform HVAC control Calibration Diagnostic
and Cooldown test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5426
Housing Assembly HVAC: Service and Repair Rear Heater-A/C Auxiliary Condenser Removal and
Installation
If vehicle is equipped with rear heater and air conditioning, it will be equipped with an auxiliary
condenser. The auxiliary condenser is mounted on the primary condenser in front of the radiator.
Both condenser must be removed as an assembly and then separated.
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
The condenser assembly must first be removed from vehicle. Refer to CONDENSER ASSEMBLY
Replacement for service procedures.
REMOVAL
1. After condenser assembly removal, place on bench for disassembly. 2. Remove (1) bolt to liquid
line on auxiliary condenser.
Rear Heat-A/C Auxiliary Condenser
3. Remove (4) attaching bolts and separate auxiliary from primary condenser.
INSTALLATION
1. Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved
wax-free refrigerant oil. Then, reverse the above
procedures.
2. Verify seals are in place on either side and on top of the radiator. 3. Evacuate and recharge
system. Refer to: "Testing and Inspection" See: Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5427
Housing Assembly HVAC: Service and Repair Rear Heater-A/C Unit Replacement and Service
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH REAR A/C, THE REFRIGERANT SYSTEM MUST
BE EMPTIED BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING
SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE.
1. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C
plumbing from rear heater A/C unit. Refer to:
"Testing and Inspection" See: Testing and Inspection
2. Hoist vehicle.
A/C Lines
3. Remove A/C lines at lower floor pan flange.
A/C Mounting
4. Remove (3) A/C unit floor mounting nuts. 5. Lower vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5428
Quarter Trim Panel
6. Remove right quarter trim panel and D-pillar trim. Refer to: "Body and Frame : Interior Trim :
Trim Panel : Service and Repair" See: Body
and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair
Lower Heater Duct
7. Remove screws securing air distribution duct to the rear wheel housing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5429
Heater Core Lines
8. Pinch off heater lines at heater core hookup.
Heater Hoses
9. Remove heater hoses at heater core.
Trim Panel Mounting Bracket
10. Remove quarter trim panel mounting bracket. 11. Remove blower motor wiring harness
connector.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5430
Upper Duct Trim
12. Remove rear upper duct trim screw.
Mounting Bolts
13. Remove (2) Heater-A/C housing mounting bolts.
A/C Unit Replacement
14. Pull up on upper A/C duct. Tilt A/C unit outward. 15. Lift the unit enough to clear floor pan.
Remove unit from the vehicle.
INSTALLATION
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 5431
Filling Heater Core
For installation, reverse the above procedures. Install new O-rings at refrigerant lines. Evacuate
and charge the refrigerant system. Fill the heater core. Test for leaks and overall performance.
NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the
vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater
core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat
opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled
completely, the following procedure can be used:
- Vehicle at room temperature.
- Engine is brought up to operating temperature.
- Front unit is OFF, temperature slides are at full HEAT position.
- Engine is at idle.
- With rear blower motor ON HIGH.
- Discharge air temperature, measured at the dual register located on the C-pillar base, is between
135° and 145° F.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair
Receiver Dryer: Service and Repair
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION .
1. Recover A/C system refrigerant.
Filter-Drier Assembly
2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan
module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator
crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location.
INSTALLATION
1. Before installation , replace both refrigerant line O-rings. Then reverse the above procedures.
Torque filter/drier mounting bolts to 45 in. lbs. ± 10. 2. Evacuate and recharge system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Capacity Specifications
Refrigerant: Capacity Specifications
R134a Single Capacity ........................................................................................................................
........................................ 0.96 kg (34 oz. or 2.13 lbs)
R134a Dual Capacity ...........................................................................................................................
....................................... 1.36 kg (48 oz. or 3.00 lbs)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Capacity Specifications > Page 5439
Refrigerant: Fluid Type Specifications
Hydrofluorocarbon (HFC), ...................................................................................................................
............................................... R-134a liquefied gas
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
5440
Refrigerant: Description and Operation
This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear
colorless liquefied gas.
R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a
small amount of R-12 in a R-134a system could cause compressor failure, refrigerant oil to sludge
and/or poor performance. Never add any other type of refrigerant to a system designed to use
R-134a refrigerant. System failure will occur.
The high pressure service port is located on the liquid line near the strut tower. The low pressure
service port is located on the suction line near the compressor manifold.
Refrigerant Recovery/Recycling Station (Typical)
When servicing a system, it is required that an air conditioning charging recovery/recycling
machine be used. Contact an automotive service equipment supplier for proper equipment. Refer
to the operating instructions provided with the equipment for proper operation.
Manifold Gauge Set - Typical
A manifold gauge set must also be used in conjunction with the charging and/or recovery/recycling
device. Only use gauges that have not been used for R-12. The service hoses on the gauge set
should have manual (turn wheel) or automatic back flow valves at the service port connector ends.
This will prevent refrigerant R-134a from being released into the atmosphere.
R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure to use the
oil that is specified on the under hood label. Due to the different characteristics of R-134a it
requires all new service procedures.
The use of R-134a will have a positive environmental impact due to it's zero ozone depletion and
low global warming impact.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and
Repair
Refrigerant Filter: Service and Repair
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION .
1. Recover A/C system refrigerant.
Filter-Drier Assembly
2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan
module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator
crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location.
INSTALLATION
1. Before installation , replace both refrigerant line O-rings. Then reverse the above procedures.
Torque filter/drier mounting bolts to 45 in. lbs. ± 10. 2. Evacuate and recharge system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Front A/C Compressor .........................................................................................................................
............................................................ 150 ml 5.0 oz.
Dual A/C Compressor ..........................................................................................................................
............................................................ 220 ml 7.4 oz.
Dual A/C Evaporator ............................................................................................................................
.............................................................. 60 ml 2.0 oz.
Condenser ...........................................................................................................................................
................................................................ 30 ml 1.0 oz.
Evaporator ...........................................................................................................................................
............................................................... 60 ml 2.0 oz. Filter-Drier ......................................................
................................................................................................................................................... 30 ml
1.0 oz.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 5448
Refrigerant Oil: Fluid Type Specifications
Synthetic-based, Polyalkylene Glycol ..................................................................................................
.......................................................................... ND-8
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Page 5449
Refrigerant Oil: Service and Repair
Refrigerant Oil Level Check
Refrigerant Oil Capacities
When an air conditioning system is first assembled, all components (except the compressor) are
refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil
in the compressor is dispersed through the lines and components. The evaporator, condenser, and
filter- drier will retain a significant amount of oil, refer to the Refrigerant Oil Capacities chart. When
a component is replaced, the specified amount of refrigerant oil must be added. When the
compressor is replaced, the amount of oil that is retained in the rest of the system must be drained
from the replacement compressor. when a line or component has ruptured and oil has escaped,
the compressor should be removed and drained. The filter-drier must be replaced along with the
ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining
components, can be measured and poured into the suction port of the compressor.
Example: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz)
of oil, and system capacity may be 220 ml (6.40 oz) of oil.
220 ml minus 90 ml = 130 ml (4.40 oz).
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG
(polyalkalene glycol).
Servicing Refrigerant Oil Level 1. Using a refrigerant recovery machine, remove refrigerant from
the A/C system. 2. Remove refrigerant lines from A/C compressor. 3. Remove compressor from
vehicle. 4. From suction port on top of compressor, drain refrigerant oil from compressor. 5. Add
system capacity minus the capacity of components that have not been replaced through suction
port on compressor. Refer to the
Refrigerant Oil Capacity Chart.
6. Install compressor, connect refrigerant lines, evacuate, and charge refrigerant system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications
Refrigerant Pressure Sensor / Switch: Specifications
Low psi control opens < 29.4 psi High psi control opens > 450 psi
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications > Page 5453
A/C Pressure Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications > Page 5454
Refrigerant Pressure Sensor / Switch: Description and Operation
SYSTEM OPERATION
A/C Pressure Transducer
A/C Pressure Transducer
The A/C Pressure Transducer monitors the refrigerant gas pressure on the high side of the system.
The transducer is located on the liquid line. The pressure transducer turns off the voltage to the
compressor clutch coil when refrigerant gas pressure drops to levels that could damage the
compressor. The transducer also is used to adjust condenser fan speeds and will turn off
compressor at high refrigerant pressures. The pressure transducer is a sealed factory calibrated
unit. It must be replaced if defective. O-ring replacement is required whenever the pressure
transducer is serviced. Be sure to use the O-ring specified for the transducer.
AIR CONDITIONING PRESSURE TRANSDUCER-PCM INPUT
The Powertrain Control Module (PCM) monitors the A/C compressor discharge (high side)
pressure through the air conditioning pressure transducer. The transducer supplies an input to the
PCM. The PCM engages the A/C compressor clutch if pressure is sufficient for A/C system
operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications > Page 5455
Refrigerant Pressure Sensor / Switch: Testing and Inspection
The work area temperature must not be below 10° C (50° F) to test the compressor clutch circuit.
Before starting to test the transducer ensure that the wire connector is clean of corrosion and
connected properly.
1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Install
scan tool (DRB):
- Go to main menu
- Select stand alone scan tool (DRB)
- Select refer to the proper year diagnostics
- Select climate control
- Select sensor display
- Select A/C high side volts
For A/C system to operate a voltage between 0.451 (Low Pressure Cutout) to 4.519 (High
Pressure Cutout is required. Voltages outside this range indicate a low or high pressure condition
and will not allow the compressor to cycle.
A/C Pressure Transducer Voltage
Refer to the A/C Pressure Transducer Voltage table for the appropriate condition(s):
1. Connect a tachometer and manifold gauge set. 2. Set control to A/C, RECIRC, and PANEL,
temperature lever on full cool and blower on high. 3. Start engine and hold at 1000 rpm with A/C
clutch engaged. 4. Engine should be warmed up with doors and windows closed. 5. Insert a
thermometer in the left center A/C outlet and operate the engine for five minutes. The A/C clutch
may cycle depending on ambient
conditions.
6. With the A/C clutch engaged, compare the discharge air temperature to the A/C Performance
Temperatures table.
A/C Performance Temperature Chart
7. If the discharge air temperature fails to meet the specifications in the performance temperature
chart. Refer to the Refrigerant Service Procedures
for further diagnosis.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications > Page 5456
Refrigerant Pressure Sensor / Switch: Service and Repair
REMOVAL
1. Disconnect the wire connector at the pressure transducer.
A/C Pressure Transducer Removal
2. Using an open end wrench, remove the transducer from the liquid line.
INSTALLATION
1. Replace transducer O-ring. 2. For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
Component Information > Locations > Component Locations
Blower Motor Relay: Component Locations
Power Distribution Center -- Sheet 8w-10-2
Rear Blower Relay
Rear Blower Motor Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
Component Information > Locations > Component Locations > Page 5462
This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
Component Information > Locations > Component Locations > Page 5463
Blower Motor Relay: Connector Locations
Power Distribution Center
Front Blower Motor Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
Component Information > Description and Operation > Front Blower Motor Relay
Blower Motor Relay: Description and Operation Front Blower Motor Relay
Circuit Operation
Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the
HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1.
The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power
Distribution Center (PDC).
The coil side of the relay is energized when the ignition switch is in the RUN position only. Power
for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the
relay
Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit
A22.
Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl
panel.
Ground for the blower motor is controlled through the blower motor resistor and the blower motor
switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
Component Information > Description and Operation > Front Blower Motor Relay > Page 5466
Blower Motor Relay: Description and Operation Rear Blower Relay
Circuit Operation
Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp
fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear
blower motor passes through the temperature sensor and one or more resistors, depending on
speed selection.
Two switches operate the rear blower motor by supplying ground; the front control switch and the
rear control switch. The front control switch must be in the ON position for the rear control switch to
operate the rear blower motor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Component Locations
Compressor Clutch Relay: Component Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Component Locations > Page 5471
Power Distribution Center -- Sheet 8w-10-2
The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is
located in the engine compartment next to the battery. A label affixed to the underside of the PDC
cover identifies the relays and fuses in the PDC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Component Locations > Page 5472
Compressor Clutch Relay: Connector Locations
Power Distribution Center
A/C Compressor Clutch Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 5473
Compressor Clutch Relay: Description and Operation
AIR CONDITIONING (A/C) CLUTCH RELAY-PCM OUTPUT
The PCM operates the air conditioning clutch relay ground circuit, The radiator fan control module
supplies battery power to the solenoid side of the relay. The air conditioning clutch relay will not
energize unless the radiator fan control module energizes. The radiator control module energizes
when the air conditioning or defrost switch is put in the ON position and the low pressure switch,
combination valve, and high pressure switch close.
With the engine operating, the PCM cycles the air conditioning clutch on and off when the A/C
switch closes with the blower motor switch in the On position. When the PCM senses low idle
speeds or wide-open-throttle through the throttle position sensor, it de-energizes the A/C clutch
relay. The relay contacts open, preventing air conditioning clutch engagement.
The air conditioning clutch relay is located in the Power Distribution Center (PDC). The PDC is
located in the engine compartment next to the battery. A label affixed to the underside of the PDC
cover identifies the relays and fuses in the PDC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Description and Operation
Air Conditioning Switch: Description and Operation
AIR CONDITIONING SWITCH SENSE-PCM INPUT
When the air conditioning or defrost switch is put in the ON position and the low pressure switch,
combination valve, and high pressure switch close, the PCM receives an A/C input. After receiving
this input, the PCM activates the A/C compressor clutch by grounding the A/C clutch relay. The
PCM also adjusts idle speed to a scheduled RPM to compensate for increased engine load.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Service and Repair > Rear Heater - A/C Switch Lamp Replacement
Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Lamp Replacement
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel HVAC Control. Refer
to Radio Bezel and HVAC Control Replacement.
Rear Heater - A/C Switch Lamp Bulb
3. Rotate bulb socket counterclockwise one quarter. 4. Pull bulb socket from switch.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Service and Repair > Rear Heater - A/C Switch Lamp Replacement > Page 5480
Air Conditioning Switch: Service and Repair Rear Heater - A/C Switch Replacement
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove radio bezel and HVAC Control.
Rear Heater - A/C Switch
3. Remove screw holding rear heater-A/C switch to radio bezel HVAC Control. 4. Disengage hook
holding bottom of switch to radio bezel HVAC Control. 5. Remove switch from radio bezel HVAC
Control.
INSTALLATION
For instrument, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor
/ Switch HVAC > Component Information > Locations
Ambient Temperature Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor
/ Switch HVAC > Component Information > Locations > Page 5484
Ambient Temperature Sensor / Switch HVAC: Diagrams
Ambient Temperature Sensor
Ambient Temperature Sensor (Sensor Side)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor
/ Switch HVAC > Component Information > Locations > Page 5485
Ambient Temperature Sensor / Switch HVAC: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Raise and support vehicle on safety stands.
3. From behind front bumper fascia, remove screw holding sensor to radiator closure panel. 4.
Remove sensor from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Description and Operation
Blower Motor Switch: Description and Operation
SYSTEM OPERATION
Rear Blower Speed Switch The rear blower speed switch controls the rear blower with the choice
of low and high speeds. when the switch is on it allows the blower speed switch located on the rear
headliner to control rear blower speed. This switch will override the rear headliner blower switch.
For operation instructions refer to the Owner's Manual. The rear blower speed switch is serviced
separately from the A/C control module. For service procedures, refer to Instrument Panel And
Gauges.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Description and Operation
Evaporator Temperature Sensor / Switch: Description and Operation
SYSTEM OPERATION
Evaporator Probe The Evaporator probe is located on the HVAC. The probe prevents evaporator
freeze-up by signaling the Powertrain Control Module to cycle the compressor ON and OFF. The
probe monitors the temperature of the refrigerant after expansion.
The evaporator probe is inserted into the evaporator between the coils. The probe is a sealed unit
and cannot be adjusted or repaired. It must be replaced if found defective.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics
Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Temperature
Diagnostics
The evaporator probe can be tested by using the INTERMITTENT LED to display the actual
temperature the sensor is reading. The HVAC control module can only display temperatures from 1
to 99 degrees. To read the temperature, perform the following:
- Set Blower motor to any speed other than OFF
- Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared. To clear
the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then,
press and hold the intermittent wipe button for 5 seconds.
- Run Diagnostics (Depress REAR WIPER and REAR WASH)
- When Diagnostics is complete, Cycle to Level 4.
Display Sequence is as follows:
- REAR WIPER LED will display the Level
- INTERMITTENT LED will display ten's digit
- Short Pause
- INTERMITTENT LED will display the one 5 digit.
The HVAC control module will continue to cycle the Level and then Temperature until the level is
changed or Calibration Diagnostics and Cooldown test is exited.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page
5494
Evaporator Temperature Sensor / Switch: Testing and Inspection Evaporator Probe Test
Evaporator Probe: Resistance Vs. Temperature Chart
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page
5495
Resistance Measurement Table
The evaporator probe is located in the unit housing and placed in the evaporator fins. The probe
prevents evaporator freeze-up. This is done by cycling the compressor clutch OFF when
evaporator temperature drops below freeze point. It cycles ON when the evaporator temperature
rises above freeze point. The evaporator probe uses a thermistor probe in a capillary tube. The
tube is inserted between the evaporator fins in the heater-A/C unit housing.
A malfunctioning evaporator probe may show symptoms such as:
- Ice blocking the airflow, or frost exiting out of the outlets and vents
- No air conditioning operation
- No power to the compressor clutch during A/C selection
The work area and vehicle must be between 16° C (60° F) and 32° C (90° F) during testing.
1. Place the vehicle in a location out of direct sunlight and allow the vehicle to come to ambient
temperature (the engine can remain warm). 2. With the engine OFF, lower the windows, and turn
on the interior blower (with the system in Fresh Air mode). 3. Place a thermometer in one of the
Instrument Panel outlets, and a second one in the intake duct (plenum area by the windshield
wipers). 4. Allow the blower to run until both temperatures readings are within 2° F of one another
and constant. 5. Remove the electrical connector from the evaporator probe and measure the
resistance of the probe with a multimeter.
6. Consult the temperature/resistance chart and table to determine whether the resistance is within
specification.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Testing and Inspection > Evaporator Probe Temperature Diagnostics > Page
5496
If the measurements fall outside the specifications, replace the evaporator probe.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Testing and Inspection > Page 5497
Evaporator Temperature Sensor / Switch: Service and Repair
REMOVAL
1. Remove the glove box. Refer to Instrument Panel and Systems.
Evaporator Probe Connector
2. Disconnect the evaporator probe connector.
Evaporator Probe Grommet
3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing.
Evaporator Probe
4. Remove evaporator probe from evaporator.
INSTALLATION
For installation, reverse the above procedures. Three holes are provided in evaporator for probe
location. When reinstalling probe, use a different hole than original one. If a new evaporator is
installed, insert the probe in the uppermost hole provided.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications
Refrigerant Pressure Sensor / Switch: Specifications
Low psi control opens < 29.4 psi High psi control opens > 450 psi
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 5501
A/C Pressure Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 5502
Refrigerant Pressure Sensor / Switch: Description and Operation
SYSTEM OPERATION
A/C Pressure Transducer
A/C Pressure Transducer
The A/C Pressure Transducer monitors the refrigerant gas pressure on the high side of the system.
The transducer is located on the liquid line. The pressure transducer turns off the voltage to the
compressor clutch coil when refrigerant gas pressure drops to levels that could damage the
compressor. The transducer also is used to adjust condenser fan speeds and will turn off
compressor at high refrigerant pressures. The pressure transducer is a sealed factory calibrated
unit. It must be replaced if defective. O-ring replacement is required whenever the pressure
transducer is serviced. Be sure to use the O-ring specified for the transducer.
AIR CONDITIONING PRESSURE TRANSDUCER-PCM INPUT
The Powertrain Control Module (PCM) monitors the A/C compressor discharge (high side)
pressure through the air conditioning pressure transducer. The transducer supplies an input to the
PCM. The PCM engages the A/C compressor clutch if pressure is sufficient for A/C system
operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 5503
Refrigerant Pressure Sensor / Switch: Testing and Inspection
The work area temperature must not be below 10° C (50° F) to test the compressor clutch circuit.
Before starting to test the transducer ensure that the wire connector is clean of corrosion and
connected properly.
1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Install
scan tool (DRB):
- Go to main menu
- Select stand alone scan tool (DRB)
- Select refer to the proper year diagnostics
- Select climate control
- Select sensor display
- Select A/C high side volts
For A/C system to operate a voltage between 0.451 (Low Pressure Cutout) to 4.519 (High
Pressure Cutout is required. Voltages outside this range indicate a low or high pressure condition
and will not allow the compressor to cycle.
A/C Pressure Transducer Voltage
Refer to the A/C Pressure Transducer Voltage table for the appropriate condition(s):
1. Connect a tachometer and manifold gauge set. 2. Set control to A/C, RECIRC, and PANEL,
temperature lever on full cool and blower on high. 3. Start engine and hold at 1000 rpm with A/C
clutch engaged. 4. Engine should be warmed up with doors and windows closed. 5. Insert a
thermometer in the left center A/C outlet and operate the engine for five minutes. The A/C clutch
may cycle depending on ambient
conditions.
6. With the A/C clutch engaged, compare the discharge air temperature to the A/C Performance
Temperatures table.
A/C Performance Temperature Chart
7. If the discharge air temperature fails to meet the specifications in the performance temperature
chart. Refer to the Refrigerant Service Procedures
for further diagnosis.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 5504
Refrigerant Pressure Sensor / Switch: Service and Repair
REMOVAL
1. Disconnect the wire connector at the pressure transducer.
A/C Pressure Transducer Removal
2. Using an open end wrench, remove the transducer from the liquid line.
INSTALLATION
1. Replace transducer O-ring. 2. For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description
and Operation
Service Port HVAC: Description and Operation
SYSTEM OPERATION
Valve Service Ports
The A/C service port valve cores are located within the A/C lines. The High Side (Discharge) valve
service port is located on the liquid line near the right frame rail. The Low Side (Suction) valve
service port is located on the suction line near the compressor.
The High Side service port is a two piece port and is serviceable. The Low Side service port is not
serviceable, the suction line would have to be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description
and Operation > Page 5508
Service Port HVAC: Service and Repair
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
The High Side service port is serviceable, the Low Side is not serviceable.
REMOVAL
1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Unscrew the High
Side service port from the liquid line. 4. Remove O-ring
INSTALLATION
For installation, reverse the above procedures.
- Install new O-ring.
- Evacuate and recharge A/C system.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming > Page 5515
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
Negative Battery Cable
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering
column and at the lower edge of the lower instrument
panel.
2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the
proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative
terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and
record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any
diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper
Body
Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes
on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to
diagnose the problem.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Airbag/Clock Spring - Service
Air Bag: Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2002 (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1988 - 1993 (AG) Daytona
1988 - 1995 (AJ) Lebaron Coupe/Convertible
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2002 (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 (KJ) Liberty
1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler
2002 (PG) PT Cruiser (International Markets)
2001 - 2002 (PT) PT Cruiser
2001 - 2002 (RG) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
1996 - 2002 (SR) Viper
2001 - 2002 (ST) Sebring Coupe/Stratus Coupe
1997 - 2002 (TJ) Wrangler
2001 - 2002 (WG) Grand Cherokee (International Markets)
1999 - 2002 (WJ) Grand Cherokee
1995 - 2001 (XJ) Cherokee
1995 - 1998 (ZG) Grand Cherokee (International Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Airbag/Clock Spring - Service > Page 5520
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Page 5521
Air Bag: Locations
Driver Airbag Module
Passenger Airbag Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Page 5522
Air Bag: Diagrams
Driver Airbag Squib
Passenger Airbag Squib
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Page 5523
Air Bag: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 5527
Air Bag Control Module: Diagrams
Airbag Control Module C1
Airbag Control Module C2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 5528
Air Bag Control Module: Description and Operation
SYSTEM OPERATION
The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The
ACM monitors the system to determine the system readiness. The ACM contains on-board
diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs.
The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or
serious injury, caused by a frontal impact of the vehicle.
The impact sensor provides verification of the direction and severity of the impact. One impact
sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a
bracket, just forward of the center console. The impact sensor is an accelerometer that senses
deceleration. The deceleration pulses are sent to a microprocessor which contains a decision
algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor
sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor
is calibrated for the specific vehicle and reacts to the severity and direction of the impact.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 5529
Air Bag Control Module: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 5530
Air Bag Control Module: Service and Repair
Negative Battery Cable
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS.
REMOVAL
1. Remove forward lower console from instrument panel, refer to Instrument Panel and Systems for
proper procedures.
Heat Duct
2. Remove screw holding lower heat duct to instrument panel support. 3. Remove heat duct from
instrument panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 5531
Instrument Panel Supports
4. Remove two bolts holding top of right support to instrument panel. 5. Remove two bolts holding
bottom of right support to floor pan. 6. Separate right instrument panel support from vehicle.
ACM Connectors
7. Disconnect two connectors from ACM.
8. Remove four bolts holding the ACM bracket assembly to floor.
INSTALLATION
WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET
THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD
NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET
INSTALLED.
CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 5532
For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with
the proper screws and tighten to 8.5 to 11.9 Nm (75 to 105 in. lbs.) torque. Do not connect battery
negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED
NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS,
PARTS, AND 2001 MODEL YEAR PROCEDURES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS.
SUBJECT: Airbag On-Off Switches
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Convertible
1994 - **2001** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
**2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - **2001** (PL) Neon
1997 (PR) Prowler
**2001 (PT) PT Cruiser**
**2001** (RS) Town & Country/Caravan/Voyager
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5537
1996 - 1997 (SR) Viper
**2001 - 2002 (ST) Sebring Coupe/Stratus Coupe**
1997 - 2001** (TJ) Wrangler
1999 - **2001** (WJ) Grand Cherokee
1997 - **2001** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
NOTE:
**SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE
OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS
DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.**
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated) and
a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule,
consumers will be authorized for on-off switches by claiming they meet any of several criteria.
Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA
authorization letter. For more information concerning the authorization process and/or the
authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you
(dealer) to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
NOTE:
FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001
CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS
REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG
SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE
CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE
AIRBAG KIT.
**FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS,
AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N
05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE
NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.**
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5538
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5539
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5540
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5541
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5542
PARTS REQUIRED:
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have~
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on
your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5543
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch
Availibility
NO: 08-17-98 Rev. C
GROUP: Electrical
DATE: Dec. 30, 1998
SUBJECT: Airbag On-Off Switches
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED
SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL
MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
**1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan**
1995 - **1999** (AB) Ram Van/Wagon
**1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon**
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/Convertible
1994 -**1999** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan/Voyager
**1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue**
1994 - **1999** (BR) Ram Pickup
**1995 - 1996 (B7) Stealth**
1998 - **1999** (DN) Durango
**1995 - 1999 (FJ) Avenger/Sebring/Talon**
1995 - **1999** (JA) Breeze/Cirrus/Stratus
1996 - **1999** (JX) Sebring Convertible
1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - **1999** (NS) Town & Country/Caravan/ Voyager
1995 - **1999** (PL) Neon
1996 - 1997 (SR) Viper
1997 - **1999** (TJ) Wrangler
1997 - **1999** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. Other applicable passenger vehicles will be announced as soon as the switches are
available. The switches are packaged in a kit containing all necessary parts (except as indicated)
and a detailed instruction sheet.
Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for
on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be
installed without the vehicle owner presenting the NHTSA authorization letter. For more information
concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety
Hotline at 1-800-424-9393.
We encourage you (dealer) to install these switches when the customer is interested in doing so
and has the necessary NHTSA authorization.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5544
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5545
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5546
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5547
PARTS REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5548
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have.
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for
your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 5549
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air
Bag Clockspring Replacement
Clockspring Assembly / Spiral Cable: Recalls Recall 04V480000: Air Bag Clockspring Replacement
Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan
1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth /
Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID
Number : 04V480000 Recall Date : OCT 05, 2004
COMPONENT: Air Bags
Potential Number Of Units Affected : 955344
SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the
clockspring, which is located in the hub of the steering wheel.
CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning
lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a
reasonable amount of time.
REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles
or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an
extended lifetime warranty under which it will replace the clockspring at no charge if it fails.
DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on
their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at
1-800-853-1403.
NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension
Technical Service Bulletin # D17 Date: 041001
Recall - Clockspring Replacement/Warranty Extension
October 2004
Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty
Models 1998-2000 (NS)
Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country
NOTE:
This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the
steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed
control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative
driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash.
Repair
Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring
assembly replaced.
Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require
any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring
assembly.
NOTE:
This recall does NOT include replacement of other airbag system components. If other components
cause illumination of the airbag warning light, the associated repair costs are the owner's
responsibility.
Parts Information
Dealers should determine which clockspring is required for each vehicle at the time appointments
are scheduled to assure that the correct part is available when the customer arrives. The
appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP
function.
Note:
Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls.
Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring
Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to
service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with
speed control and radio controls. Additional clockspring assemblies may be ordered as necessary.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 5562
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Use one of the labor operation numbers and time allowances shown.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle list
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this
recall in the near future.
Vehicle Lists, Global Recall System, VIP and Dealer Follow up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed
a copy of their vehicle (VIN) list with the dealer recall notification letter.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule appointments for this
repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
DaimlerChrysler Mobile Service approved repair.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 5563
Customer Services Field Operations Daimler Chrysler Corporation
Service Procedure
1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if
it is functioning properly. Proceed to Step 4.
IMPORTANT:
If an owner requests this recall service on a minivan that has more than 70,000 miles and an
AIRBAG light that operates normally even though the owner letter clearly states that no action is
necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3
of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present.
2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the
ON position.
3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC).
> If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring
assembly MUST be replaced. Erase the DTC and continue with Step 4.
> If there are no DTC's or if any other airbag system DTC is present, the recall service procedure
does not apply. Diagnosis and repairs are the owner's responsibility.
4. Place the front wheels in the straight-ahead position.
5. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1).
7. Pull the airbag module away from the steering wheel far enough to access the wire harness
connectors on the back of the airbag module.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 5564
8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire
connector on the back of the airbag module (Figure 2).
9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag
module by firmly grasping and pulling, or gently prying, the connector.
NOTE:
Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module
connector receptacle.
10. Disconnect the clockspring wire harness connectors from the speed control switches and
steering wheel mounted radio controls (if equipped) (Figure 2).
11. Remove the airbag module and set it aside.
12. Remove the steering wheel nut.
13. Remove the steering wheel damper from the steering wheel (if equipped).
14. Remove the steering wheel from the steering column using a steering wheel puller (Special
Tool C-3428-B).
15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column,
then remove the shrouds from the steering column (Figure 3).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 5565
16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4).
17. Remove the clockspring from the multi-function switch by depressing the two tabs on the
clockspring (Figure 5). Discard the clockspring assembly.
18. Slide the new clockspring over the steering column shaft until the clockspring latches engage
the multi-function switch housing (Figure 5).
19. Connect the wire harness connectors to the clockspring assembly (Figure 4).
20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws
securely.
21. Install the steering wheel onto the steering column shaft.
22. Install the steering wheel damper (if equipped).
23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m).
24. Connect the clockspring wire harness connectors to the speed control switches and steering
wheel mounted radio controls (if equipped) (Figure 2).
25. Connect the clockspring airbag wire harness connector to the back of the airbag module
(Figure 2).
26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector
on the back of the airbag module (Figure 2).
27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire
harnesses in the steering wheel hub area are not pinched
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 5566
between the airbag module and the steering wheel.
28. From the backside of the steering wheel, install the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm).
29. With the ignition switch in the ON position, connect the negative battery cable.
30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then turn it back to the ON position.
31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 5567
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning
Lamp ON Intermittently/Constantly
Clockspring Assembly / Spiral Cable: Customer Interest Air Bags - Warning Lamp ON
Intermittently/Constantly
NUMBER: 08-011-02
GROUP: Electrical
DATE: Aug. 19, 2002
SUBJECT: Air Bag Warning Indicator Lamp On
OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either
intermittently or constantly.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Market)
SYMPTOM/CONDITION:
The air bag warning indicator lamp may be on intermittently or constantly.
DIAGNOSIS:
If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is
DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body
Diagnostic Manual leads to replace the clockspring because of high resistance, perform the
following additional diagnostic procedure.
DISCUSSION:
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing and replacing any component. When
diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool
8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test
components and wiring. Only replace and/or repair the component or wiring that has been
identified with the 8310 Airbag Load Tool and the DRBIII(R).
NOTE:
AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310
AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT.
NOTE:
RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG
WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN
INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE
CLOCKSPRING FOR THE DRIVER'S SQUIB.
PARTS REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning
Lamp ON Intermittently/Constantly > Page 5573
EQUIPMENT POSSIBLY REQUIRED:
REPAIR PROCEDURE:
1. Determine if the Driver Squib Circuit Open DTC is active or stored.
a. If DTC is active proceed to step 2.
b. If DTC is stored proceed to step 3.
2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring,
verify the DTC remains by turning the steering wheel to the full left lock position, back to the full
right lock position, and then back to the centered position. This can be verified by using the 8310
Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From
the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics,
select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation
from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present
at this time, proceed to step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock
position, back to the full right lock position, and then back to the centered position and verify that
the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the
8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R).
From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002
Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor
Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to
lock, continue with step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning
Lamp ON Intermittently/Constantly > Page 5574
TIME ALLOWANCE:
FAILURE CODE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5579
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5580
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5581
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5582
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5583
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 5584
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air Bag Clockspring Replacement
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 04V480000: Air Bag
Clockspring Replacement
Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan
1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth /
Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID
Number : 04V480000 Recall Date : OCT 05, 2004
COMPONENT: Air Bags
Potential Number Of Units Affected : 955344
SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the
clockspring, which is located in the hub of the steering wheel.
CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning
lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a
reasonable amount of time.
REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles
or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an
extended lifetime warranty under which it will replace the clockspring at no charge if it fails.
DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on
their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at
1-800-853-1403.
NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension
Technical Service Bulletin # D17 Date: 041001
Recall - Clockspring Replacement/Warranty Extension
October 2004
Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty
Models 1998-2000 (NS)
Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country
NOTE:
This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the
steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed
control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative
driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash.
Repair
Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring
assembly replaced.
Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require
any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring
assembly.
NOTE:
This recall does NOT include replacement of other airbag system components. If other components
cause illumination of the airbag warning light, the associated repair costs are the owner's
responsibility.
Parts Information
Dealers should determine which clockspring is required for each vehicle at the time appointments
are scheduled to assure that the correct part is available when the customer arrives. The
appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP
function.
Note:
Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls.
Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring
Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to
service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with
speed control and radio controls. Additional clockspring assemblies may be ordered as necessary.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
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submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Use one of the labor operation numbers and time allowances shown.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle list
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this
recall in the near future.
Vehicle Lists, Global Recall System, VIP and Dealer Follow up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed
a copy of their vehicle (VIN) list with the dealer recall notification letter.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule appointments for this
repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
DaimlerChrysler Mobile Service approved repair.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
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Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5595
Customer Services Field Operations Daimler Chrysler Corporation
Service Procedure
1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if
it is functioning properly. Proceed to Step 4.
IMPORTANT:
If an owner requests this recall service on a minivan that has more than 70,000 miles and an
AIRBAG light that operates normally even though the owner letter clearly states that no action is
necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3
of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present.
2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the
ON position.
3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC).
> If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring
assembly MUST be replaced. Erase the DTC and continue with Step 4.
> If there are no DTC's or if any other airbag system DTC is present, the recall service procedure
does not apply. Diagnosis and repairs are the owner's responsibility.
4. Place the front wheels in the straight-ahead position.
5. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1).
7. Pull the airbag module away from the steering wheel far enough to access the wire harness
connectors on the back of the airbag module.
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8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire
connector on the back of the airbag module (Figure 2).
9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag
module by firmly grasping and pulling, or gently prying, the connector.
NOTE:
Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module
connector receptacle.
10. Disconnect the clockspring wire harness connectors from the speed control switches and
steering wheel mounted radio controls (if equipped) (Figure 2).
11. Remove the airbag module and set it aside.
12. Remove the steering wheel nut.
13. Remove the steering wheel damper from the steering wheel (if equipped).
14. Remove the steering wheel from the steering column using a steering wheel puller (Special
Tool C-3428-B).
15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column,
then remove the shrouds from the steering column (Figure 3).
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16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4).
17. Remove the clockspring from the multi-function switch by depressing the two tabs on the
clockspring (Figure 5). Discard the clockspring assembly.
18. Slide the new clockspring over the steering column shaft until the clockspring latches engage
the multi-function switch housing (Figure 5).
19. Connect the wire harness connectors to the clockspring assembly (Figure 4).
20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws
securely.
21. Install the steering wheel onto the steering column shaft.
22. Install the steering wheel damper (if equipped).
23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m).
24. Connect the clockspring wire harness connectors to the speed control switches and steering
wheel mounted radio controls (if equipped) (Figure 2).
25. Connect the clockspring airbag wire harness connector to the back of the airbag module
(Figure 2).
26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector
on the back of the airbag module (Figure 2).
27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire
harnesses in the steering wheel hub area are not pinched
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between the airbag module and the steering wheel.
28. From the backside of the steering wheel, install the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm).
29. With the ignition switch in the ON position, connect the negative battery cable.
30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then turn it back to the ON position.
31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
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Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Air Bags - Warning Lamp ON
Intermittently/Constantly
NUMBER: 08-011-02
GROUP: Electrical
DATE: Aug. 19, 2002
SUBJECT: Air Bag Warning Indicator Lamp On
OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either
intermittently or constantly.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Market)
SYMPTOM/CONDITION:
The air bag warning indicator lamp may be on intermittently or constantly.
DIAGNOSIS:
If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is
DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body
Diagnostic Manual leads to replace the clockspring because of high resistance, perform the
following additional diagnostic procedure.
DISCUSSION:
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing and replacing any component. When
diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool
8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test
components and wiring. Only replace and/or repair the component or wiring that has been
identified with the 8310 Airbag Load Tool and the DRBIII(R).
NOTE:
AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310
AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT.
NOTE:
RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG
WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN
INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE
CLOCKSPRING FOR THE DRIVER'S SQUIB.
PARTS REQUIRED:
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EQUIPMENT POSSIBLY REQUIRED:
REPAIR PROCEDURE:
1. Determine if the Driver Squib Circuit Open DTC is active or stored.
a. If DTC is active proceed to step 2.
b. If DTC is stored proceed to step 3.
2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring,
verify the DTC remains by turning the steering wheel to the full left lock position, back to the full
right lock position, and then back to the centered position. This can be verified by using the 8310
Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From
the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics,
select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation
from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present
at this time, proceed to step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock
position, back to the full right lock position, and then back to the centered position and verify that
the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the
8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R).
From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002
Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor
Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to
lock, continue with step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual.
POLICY: Reimbursable within the provisions of the warranty.
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TIME ALLOWANCE:
FAILURE CODE:
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Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2002 (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1988 - 1993 (AG) Daytona
1988 - 1995 (AJ) Lebaron Coupe/Convertible
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2002 (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 (KJ) Liberty
1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler
2002 (PG) PT Cruiser (International Markets)
2001 - 2002 (PT) PT Cruiser
2001 - 2002 (RG) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
1996 - 2002 (SR) Viper
2001 - 2002 (ST) Sebring Coupe/Stratus Coupe
1997 - 2002 (TJ) Wrangler
2001 - 2002 (WG) Grand Cherokee (International Markets)
1999 - 2002 (WJ) Grand Cherokee
1995 - 2001 (XJ) Cherokee
1995 - 1998 (ZG) Grand Cherokee (International Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
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Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5610
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
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Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
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Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
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Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
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HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
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Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
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Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5620
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Air Bags - Warning Lamp ON
Intermittently/Constantly
NUMBER: 08-011-02
GROUP: Electrical
DATE: Aug. 19, 2002
SUBJECT: Air Bag Warning Indicator Lamp On
OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either
intermittently or constantly.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Market)
SYMPTOM/CONDITION:
The air bag warning indicator lamp may be on intermittently or constantly.
DIAGNOSIS:
If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is
DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body
Diagnostic Manual leads to replace the clockspring because of high resistance, perform the
following additional diagnostic procedure.
DISCUSSION:
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing and replacing any component. When
diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool
8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test
components and wiring. Only replace and/or repair the component or wiring that has been
identified with the 8310 Airbag Load Tool and the DRBIII(R).
NOTE:
AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310
AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT.
NOTE:
RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG
WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN
INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE
CLOCKSPRING FOR THE DRIVER'S SQUIB.
PARTS REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 5626
EQUIPMENT POSSIBLY REQUIRED:
REPAIR PROCEDURE:
1. Determine if the Driver Squib Circuit Open DTC is active or stored.
a. If DTC is active proceed to step 2.
b. If DTC is stored proceed to step 3.
2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring,
verify the DTC remains by turning the steering wheel to the full left lock position, back to the full
right lock position, and then back to the centered position. This can be verified by using the 8310
Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From
the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics,
select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation
from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present
at this time, proceed to step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock
position, back to the full right lock position, and then back to the centered position and verify that
the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the
8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R).
From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002
Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor
Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to
lock, continue with step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual.
POLICY: Reimbursable within the provisions of the warranty.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 5627
TIME ALLOWANCE:
FAILURE CODE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-010-01 > May > 01 > Airbag/Clock Spring - Service
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2002 (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1988 - 1993 (AG) Daytona
1988 - 1995 (AJ) Lebaron Coupe/Convertible
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2002 (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 (KJ) Liberty
1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler
2002 (PG) PT Cruiser (International Markets)
2001 - 2002 (PT) PT Cruiser
2001 - 2002 (RG) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
1996 - 2002 (SR) Viper
2001 - 2002 (ST) Sebring Coupe/Stratus Coupe
1997 - 2002 (TJ) Wrangler
2001 - 2002 (WG) Grand Cherokee (International Markets)
1999 - 2002 (WJ) Grand Cherokee
1995 - 2001 (XJ) Cherokee
1995 - 1998 (ZG) Grand Cherokee (International Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5632
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
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> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5637
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
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> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5638
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
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> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5639
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
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> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5640
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
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> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5641
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
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> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 5642
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
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Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air Bag Clockspring Replacement
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 04V480000: Air Bag
Clockspring Replacement
Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan
1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth /
Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID
Number : 04V480000 Recall Date : OCT 05, 2004
COMPONENT: Air Bags
Potential Number Of Units Affected : 955344
SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the
clockspring, which is located in the hub of the steering wheel.
CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning
lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a
reasonable amount of time.
REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles
or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an
extended lifetime warranty under which it will replace the clockspring at no charge if it fails.
DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on
their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at
1-800-853-1403.
NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
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Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension
Technical Service Bulletin # D17 Date: 041001
Recall - Clockspring Replacement/Warranty Extension
October 2004
Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty
Models 1998-2000 (NS)
Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country
NOTE:
This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the
steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed
control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative
driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash.
Repair
Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring
assembly replaced.
Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require
any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring
assembly.
NOTE:
This recall does NOT include replacement of other airbag system components. If other components
cause illumination of the airbag warning light, the associated repair costs are the owner's
responsibility.
Parts Information
Dealers should determine which clockspring is required for each vehicle at the time appointments
are scheduled to assure that the correct part is available when the customer arrives. The
appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP
function.
Note:
Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls.
Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring
Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to
service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with
speed control and radio controls. Additional clockspring assemblies may be ordered as necessary.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims
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> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5652
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Use one of the labor operation numbers and time allowances shown.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle list
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this
recall in the near future.
Vehicle Lists, Global Recall System, VIP and Dealer Follow up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed
a copy of their vehicle (VIN) list with the dealer recall notification letter.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule appointments for this
repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
DaimlerChrysler Mobile Service approved repair.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5653
Customer Services Field Operations Daimler Chrysler Corporation
Service Procedure
1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if
it is functioning properly. Proceed to Step 4.
IMPORTANT:
If an owner requests this recall service on a minivan that has more than 70,000 miles and an
AIRBAG light that operates normally even though the owner letter clearly states that no action is
necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3
of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present.
2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the
ON position.
3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC).
> If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring
assembly MUST be replaced. Erase the DTC and continue with Step 4.
> If there are no DTC's or if any other airbag system DTC is present, the recall service procedure
does not apply. Diagnosis and repairs are the owner's responsibility.
4. Place the front wheels in the straight-ahead position.
5. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1).
7. Pull the airbag module away from the steering wheel far enough to access the wire harness
connectors on the back of the airbag module.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5654
8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire
connector on the back of the airbag module (Figure 2).
9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag
module by firmly grasping and pulling, or gently prying, the connector.
NOTE:
Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module
connector receptacle.
10. Disconnect the clockspring wire harness connectors from the speed control switches and
steering wheel mounted radio controls (if equipped) (Figure 2).
11. Remove the airbag module and set it aside.
12. Remove the steering wheel nut.
13. Remove the steering wheel damper from the steering wheel (if equipped).
14. Remove the steering wheel from the steering column using a steering wheel puller (Special
Tool C-3428-B).
15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column,
then remove the shrouds from the steering column (Figure 3).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5655
16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4).
17. Remove the clockspring from the multi-function switch by depressing the two tabs on the
clockspring (Figure 5). Discard the clockspring assembly.
18. Slide the new clockspring over the steering column shaft until the clockspring latches engage
the multi-function switch housing (Figure 5).
19. Connect the wire harness connectors to the clockspring assembly (Figure 4).
20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws
securely.
21. Install the steering wheel onto the steering column shaft.
22. Install the steering wheel damper (if equipped).
23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m).
24. Connect the clockspring wire harness connectors to the speed control switches and steering
wheel mounted radio controls (if equipped) (Figure 2).
25. Connect the clockspring airbag wire harness connector to the back of the airbag module
(Figure 2).
26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector
on the back of the airbag module (Figure 2).
27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire
harnesses in the steering wheel hub area are not pinched
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5656
between the airbag module and the steering wheel.
28. From the backside of the steering wheel, install the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm).
29. With the ignition switch in the ON position, connect the negative battery cable.
30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then turn it back to the ON position.
31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 5657
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 5662
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Page 5663
Clockspring Assembly / Spiral Cable: Diagrams
Clockspring C1
Clockspring C2
Clockspring C3
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Page 5664
Clockspring Assembly / Spiral Cable: Description and Operation
SYSTEM OPERATION
The clockspring is snapped into a plastic mounting platform on the steering column behind the
steering wheel. The clockspring is used to maintain a continuous electrical circuit between the
wiring harness and the driver's airbag module. This assembly consists of a flat ribbon like
electrically conductive tape which winds and unwinds with the steering wheel rotation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Page 5665
Clockspring Assembly / Spiral Cable: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Page 5666
Clockspring Assembly / Spiral Cable: Adjustments
If the rotating tape wire coil.in the clockspring is not positioned properly with the steering wheel and
the front wheels, the clockspring may fail. The following procedure MUST BE USED to center the
clockspring if it is not known to be properly positioned, or if the front wheels were moved from the
straight ahead position.
Negative Battery Cable
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIR BAG
COMPONENTS.
1. Adjust the steering wheel so that the tires are in a straight ahead position. 2. Remove Driver
Airbag Module from steering wheel. 3. Disconnect wire connectors from back of airbag module. 4.
Remove steering wheel.
Clockspring Locking Tabs
5. Depress the two plastic locking pins to disengage lock mechanism. 6. With lock mechanism
disengaged, rotate the clockspring rotor clockwise until the rotor stops. Do not apply excessive
force. 7. From the end of travel, rotate the rotor three turns counterclockwise. The wires should end
up at the top. Release locking pins to engage
clockspring lock mechanism.
8. Install steering wheel and airbag. 9. Do not connect battery negative cable. Refer to Airbag
System Test procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Page 5667
Clockspring Assembly / Spiral Cable: Service and Repair
Negative Battery Cable
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
REMOVAL
1. Position steering wheel and front wheels straight ahead. 2. Release hood latch and open hood.
Airbag / Horn Switch
3. Remove driver airbag from steering wheel. 4. Disconnect wire connectors from back of airbag
module. 5. Disconnect the 2-way connector from remote radio control harness.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Page 5668
6. Remove steering wheel.
Airbag Clockspring
7. Remove steering column shrouds. 8. Disconnect 2-way and 5-way connectors between the
clockspring and the instrument panel wiring harness.
Clockspring Locking Tabs
9. Remove clockspring from housing assembly by depressing the two tabs on the clockspring.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Page 5669
INSTALLATION
For installation, reverse the above procedures. Do not connect battery negative cable. Refer to
Diagnosis and Testing for Airbag System Test procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations
Impact Sensor: Locations
Instrument Panel Supports
The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations
> Page 5673
Impact Sensor: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component
Information > Testing and Inspection
Malfunction Lamp / Indicator: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time
Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time
NUMBER: 23-008-00 Rev. B
GROUP: Body
DATE: Nov. 24, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED
JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS.
SUBJECT: Child Seat Tether Anchors
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) Lebaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2001 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 JA Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
**2000 (TJ) Wrangler**
1999 - 2000 (WJ) Grand Cherokee
1989 - **2000** (XJ) Cherokee/Wagoneer
1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION
NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER
WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING
DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY
ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS.
DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in
the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the
performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit
for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat
tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit
containing all necessary parts and a detailed instruction sheet.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time > Page 5681
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time > Page 5682
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time > Page 5683
PARTS REQUIRED:
POLICY: Customer Satisfaction
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time > Page 5684
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time > Page 5685
TIME ALLOWANCE:
FAILURE CODE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair
Knee Diverter: Service and Repair
Knee Blocker Reinforcement
REMOVAL
1. Remove lower steering column cover.
Knee Blocker Reinforcement
2. Remove screws holding knee blocker reinforcement to instrument panel. 3. Remove knee
blocker reinforcement from vehicle.
INSTALLATION
1. Place reinforcement in position. 2. Install screws to hold knee blocker reinforcement to
instrument panel. 3. Install lower steering column cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 5693
Air Bag Control Module: Diagrams
Airbag Control Module C1
Airbag Control Module C2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 5694
Air Bag Control Module: Description and Operation
SYSTEM OPERATION
The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The
ACM monitors the system to determine the system readiness. The ACM contains on-board
diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs.
The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or
serious injury, caused by a frontal impact of the vehicle.
The impact sensor provides verification of the direction and severity of the impact. One impact
sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a
bracket, just forward of the center console. The impact sensor is an accelerometer that senses
deceleration. The deceleration pulses are sent to a microprocessor which contains a decision
algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor
sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor
is calibrated for the specific vehicle and reacts to the severity and direction of the impact.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 5695
Air Bag Control Module: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 5696
Air Bag Control Module: Service and Repair
Negative Battery Cable
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS.
REMOVAL
1. Remove forward lower console from instrument panel, refer to Instrument Panel and Systems for
proper procedures.
Heat Duct
2. Remove screw holding lower heat duct to instrument panel support. 3. Remove heat duct from
instrument panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 5697
Instrument Panel Supports
4. Remove two bolts holding top of right support to instrument panel. 5. Remove two bolts holding
bottom of right support to floor pan. 6. Separate right instrument panel support from vehicle.
ACM Connectors
7. Disconnect two connectors from ACM.
8. Remove four bolts holding the ACM bracket assembly to floor.
INSTALLATION
WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET
THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD
NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET
INSTALLED.
CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 5698
For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with
the proper screws and tighten to 8.5 to 11.9 Nm (75 to 105 in. lbs.) torque. Do not connect battery
negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming > Page 5704
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
Negative Battery Cable
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering
column and at the lower edge of the lower instrument
panel.
2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the
proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative
terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and
record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any
diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper
Body
Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes
on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to
diagnose the problem.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation
Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether
Installation
NUMBER: 23-029-08
GROUP: Body
DATE: October 24, 2008
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED
NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR
MILEAGE.
SUBJECT: Child Seat Tether Anchor Installation
OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on
Customer Request.
NOTE:
Dealers are encouraged to honor any customers request for the installation of the Child Seat
Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or
mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for
reimbursement detail.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) Lebaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shawdow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2001 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5710
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
2000 (TJ) Wrangler
1999 - 2000 (WJ) Grand Cherokee
1989 - 2000 (XJ) Cherokee/Wagoneer
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in
the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve
the performance of child restraints in collisions. Because of the publicity that has accompanied the
"Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware.
Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether
anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet.
NOTE:
This bulletin is provided to identify the parts and labor operation numbers necessary to install a
Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer
request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits
regardless of vehicle age or mileage.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5711
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5712
PARTS REQUIRED:
POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5713
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5714
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5715
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5716
Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts
Identification
NUMBER: 23-35-99 Rev. A
GROUP: Body
DATE: Oct. 1, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED
SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME
ALLOWANCES.
SUBJECT: Child Seat Tether Anchors
NOTE:
THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS.
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) LeBaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2000 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
1999 - 2000 (WJ) Grand Cherokee
1989 - 2000 (XJ) Cherokee/Wagoneer
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION
NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER
WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING
DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY
ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS.
DISCUSSION
User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model
Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child
restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program,
owners of earlier products are expected to approach dealers for the free provision and installation
of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the
selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary
parts and a
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5717
detailed instruction sheet.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5718
PARTS REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5719
POLICY: Customer Satisfaction
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5720
TIME ALLOWANCE:
Failure Code: CG - Customer Satisfaction
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5721
Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part
Numbers & Labor Time
NUMBER: 23-008-00 Rev. B
GROUP: Body
DATE: Nov. 24, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED
JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS.
SUBJECT: Child Seat Tether Anchors
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) Lebaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2001 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 JA Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
**2000 (TJ) Wrangler**
1999 - 2000 (WJ) Grand Cherokee
1989 - **2000** (XJ) Cherokee/Wagoneer
1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION
NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER
WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING
DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY
ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS.
DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in
the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the
performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit
for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat
tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit
containing all necessary parts and a detailed instruction sheet.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5722
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5723
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5724
PARTS REQUIRED:
POLICY: Customer Satisfaction
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5725
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 5726
TIME ALLOWANCE:
FAILURE CODE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > NHTSA02V076000 > Mar > 02 > Recall 02V076000: Seat Belt May Become
Inoperative
Seat Belt: Recalls Recall 02V076000: Seat Belt May Become Inoperative
Defect: On certain minivans, some trim material can loosen and drop into the rear outboard seat
belt assembly, causing the seat belt to become inoperative. In the event of a crash, the seat
occupant may not be properly restrained, increasing the risk of personal injury.
Remedy: Dealers will replace the trim with foam blockers and inspect and replace all 3rd row seat
belt assemblies. The manufacturer has reported that owner notification is expected to begin during
June 2002. Owners who do not receive the free remedy within a reasonable time should contact
DaimlerChrysler at 1-800-853-1403.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA02V076000 > Mar > 02 > Recall 02V076000: Seat
Belt May Become Inoperative
Seat Belt: All Technical Service Bulletins Recall 02V076000: Seat Belt May Become Inoperative
Defect: On certain minivans, some trim material can loosen and drop into the rear outboard seat
belt assembly, causing the seat belt to become inoperative. In the event of a crash, the seat
occupant may not be properly restrained, increasing the risk of personal injury.
Remedy: Dealers will replace the trim with foam blockers and inspect and replace all 3rd row seat
belt assemblies. The manufacturer has reported that owner notification is expected to begin during
June 2002. Owners who do not receive the free remedy within a reasonable time should contact
DaimlerChrysler at 1-800-853-1403.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams
Seat Belt Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement
Technical Service Bulletin # 978 Date: 010801
Recall - Seat Belt Retractor Replacement
August 2001
Dealer Service Instructions for:
Safety Recall No. 978 -- Front Seat Belt Retractors
Models
1999 (AB) Dodge Ram Van/Wagon
NOTE:
This recall applies only to the above vehicles built from December 18, 1998 through January 29,
1999 (MDH 1218XX through 0129XX)
1999 (AN) Dodge Dakota
NOTE:
This recall applies only to the above vehicles built from December 6, 1998 through January 15,
1999 (MDH 1206XX through 0115XX)
1999 (DN) Dodge Durango
NOTE:
This recall applies only to the above vehicles built from December 6, 1998 through January 18,
1999 (MDH 1206XX through 0118XX)
1999 (LH) Chrysler Concorde, LHS and 300M and Dodge Intrepid
NOTE:
This recall applies only to the above vehicles built from December 6, 1998 through January 19,
1999 (MDH 1206XX through 0119XX)
1999 (NS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth
Voyager/Grand Voyager
NOTE:
This recall applies only to the above vehicles built from December 6, 1998 through January 19,
1999 (MDH 1206XX through 0119XX)
1999 (WJ) Jeep Grand Cherokee
NOTE:
This recall applies only to the above vehicles built from December 6, 1998 through January 19,
1999 (MDH 1206XX through 0119XX)
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.
Subject
One or both of the front seat belt retractor assemblies on about 150,000 of the above vehicles may
not comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 209. An
improperly manufactured internal lever may not lock the seat belt retractor. This could allow
increased risk of injury to a front seat occupant in certain accident conditions.
Repair
The front seat belt retractor assembly(s) must be replaced.
Parts Information
No parts will be distributed initially for this recall. Dealers should determine which Seat Belt
Retractor package is required for each vehicle at the time appointments are scheduled to assure
that the correct parts are available when the customer arrives. Each package contains a right and a
left front seat belt retractor (except as noted) . The retractor package for the vehicle to be serviced
may be determined by:
^ Using the part code in the third column of the VIN list along with the table (involved dealers);
^ Using the VIN and part number list electronically transmitted to DIAL System Function 53
(involved dealers); or
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement
> Page 5751
^ Entering the VIN into the DIAL VIP System (sales code information) along with the table (all
dealers) shown.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Use one of the labor operation numbers and time allowances shown.
Parts Return
Not required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement
> Page 5752
Dealer Notification and Vehicle List
All dealers will receive a copy of this dealer recall notification letter by firs class mail. Two additional
copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the
near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the
same street address) will receive a list of their involved vehicles. The vehicle list is arranged in
Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed.
The lists are for dealer reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer injury as
needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD978".
Owner Notification and Service Scheduling
All involved vehicle owners known to Daimlerchrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
Daimlerchrysler Mobile Service approved repair.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
AB Vans/Wagons
IMPORTANT: Ram Vans/Wagons equipped with a sliding door require right (passenger side) front
seat belt retractor assembly replacement only.
1. Open the passenger side doors.
2. Using a small flat blade, pry the turning loop cover open.
3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster.
4. Remove the retractor/seat belt lower anchor bolt from the front seat riser.
5. Remove and discard the retractor assembly.
6. Install the new retractor assembly.
7. Install the retractor/seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
8. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
9. Close the turning loop cover.
10. For vehicles equipped with dual hinged side doors, repeat Steps 1-9 for the driver's side of the
vehicle.
AN Trucks
IMPORTANT:
Dakota trucks require left (driver side) front seat belt retractor assembly replacement only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement
> Page 5753
1. Open the driver's side door.
2. Remove the driver's door sill plate.
3. For Club Cab trucks, remove the cab back trim panel.
4. Using a small flat blade, pry the front seat belt turning loop cover open.
5. Remove the front seat belt turning loop attaching bolt and disconnect the turning loop from the
height adjuster.
6. For Club Cab trucks, pry the rear seat belt turning loop cover open using a small flat blade.
7. For Club Cab trucks, remove the rear seat belt turning loop attaching bolt and disconnect the
turning loop from the height adjuster.
8. Remove the quarter (B-Pillar) trim panel.
9. Remove the lower seat belt anchor bolt.
10. Remove the anchor bolt that attaches the retractor to the B-pillar.
11. Disconnect the retractor electrical connector (if equipped).
12. Remove and discard the retractor assembly.
13. Install the new retractor assembly.
14. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm).
15. Connect the retractor electrical connector (if equipped).
16. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm).
17. Install the quarter (B-pillar) trim panel.
18. For Club Cab trucks, install the rear seat belt turning loop anchor bolt. Tighten the bolt to 30
ft-lbs (41 Nm).
19. Install the front seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm).
20. Close the turning loop cover(s).
21. For Club Cab trucks, install the cab back trim panel.
22. Install the door sill plate.
DN Vehicles
1. Open the driver's door.
2. Using a small flat blade, pry the turning loop cover open.
3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster.
4. Remove the lower seat belt anchor bolt from the driver's seat.
5. Remove the driver's door sill plate.
6. Remove the upper B-Pillar trim panel.
7. Remove the lower B-Pillar trim panel.
8. Disconnect the retractor electrical connector.
9. Remove the anchor bolt that attaches the retractor to the B-pillar.
10. Remove and discard the retractor assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement
> Page 5754
11. Remove the anti-rotation tab from the new retractor assembly and then install the new retractor
assembly.
12. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
13. Connect the retractor electrical connector.
14. Install the lower B-pillar trim panel.
15. Install the upper B-pillar trim panel.
16. Install the driver's door sill plate.
17. Install the lower seat belt anchor bolt (Figure 3). Tighten the bolt to 17 ft-lbs (23 Nm)
18. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
19. Close the turning loop cover.
20. Repeat Steps 1-19 for the passenger side of the vehicle.
LH Vehicles
1. Using a small flat blade, pry the turning loop cover open.
2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster.
3. Remove the seat belt/retractor lower anchor bolt.
4. Remove the upper B-Pillar trim panel.
5. Remove the lower B-Pillar trim panel.
6. Remove and discard the retractor assembly.
7. Install the new retractor assembly.
8. Install the lower B-pillar trim panel.
9. Install the upper B-pillar trim panel.
10. Install the seat belt/retractor lower anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
11. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
12. Close the turning loop cover.
13. Repeat Steps 1-12 for the other side of the vehicle.
WJ Vehicles
1. Open the driver's door.
2. Using a small flat blade, pry the turning loop cover open.
3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster.
4. Remove the lower seat belt anchor bolt.
5. Remove the driver's door sill plate.
6. Remove the lower B-Pillar trim panel.
7. Remove and discard the retractor assembly.
8. Install the new retractor assembly.
9. Install the lower B-pillar trim panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt Retractor Replacement
> Page 5755
10. Install the driver's door sill plate.
11. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
12. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
13. Close the turning loop cover.
14. Repeat Steps 1-13 for the passenger side of the vehicle.
NS Minivans
IMPORTANT:
Town & Country minivans equipped with a taupe-colored leather interior require left (driver side)
front seat belt retractor assembly replacement only.
1. Using a small flat blade, pry the turning loop cover open.
2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster.
3. Remove the upper B-Pillar trim panel.
4. Remove the seat belt floor anchor bolt.
5. Remove the lower B-Pillar trim panel. (On three door models, remove the upper bolster from the
left quarter trim panel, remove the five screws across the top and three screws at the front of the
trim panel and then pull the front of the quarter trim panel back far enough to access the retractor
assembly.)
6. Remove the anchor bolt that attaches the retractor to the B-pillar.
7. Disconnect the retractor electrical connector, if equipped, and then remove and discard the
retractor assembly.
8. Connect the retractor electrical connector, if equipped, and then install the new retractor
assembly.
9. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
10. Install the lower B-pillar trim panel (or left quarter trim panel on three door models).
11. Install the seat belt floor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). Make sure that the
floor anchor is properly oriented (30 outboard).
12. Install the upper B-pillar trim panel.
13. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
14. Close the turning loop cover.
15. Repeat Steps 1-14 for the other side of the vehicle if necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Recalls for Seat Belt Retractor: > NHTSA01V119000 > Apr > 01 > Recall 01V119000: Seat
Belt Retractor
Seat Belt Retractor: Recalls Recall 01V119000: Seat Belt Retractor
Vehicle Description: Certain van, wagon, pickup trucks, passenger and sport utility vehicles, fail to
comply with requirements of FMVSS No. 209, "Seat Belt Assemblies." The front seat belt retractor
may not comply with the requirements of the standard.
If the retractor does not work properly, it will not adequately protect occupants in the event of a
crash.
Dealers will replace the seat belt retractor. DaimlerChrysler has not yet provided NHTSA with an
owner notification schedule for this campaign.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt
Retractor Replacement
Technical Service Bulletin # 978 Date: 010801
Recall - Seat Belt Retractor Replacement
August 2001
Dealer Service Instructions for:
Safety Recall No. 978 -- Front Seat Belt Retractors
Models
1999 (AB) Dodge Ram Van/Wagon
NOTE:
This recall applies only to the above vehicles built from December 18, 1998 through January 29,
1999 (MDH 1218XX through 0129XX)
1999 (AN) Dodge Dakota
NOTE:
This recall applies only to the above vehicles built from December 6, 1998 through January 15,
1999 (MDH 1206XX through 0115XX)
1999 (DN) Dodge Durango
NOTE:
This recall applies only to the above vehicles built from December 6, 1998 through January 18,
1999 (MDH 1206XX through 0118XX)
1999 (LH) Chrysler Concorde, LHS and 300M and Dodge Intrepid
NOTE:
This recall applies only to the above vehicles built from December 6, 1998 through January 19,
1999 (MDH 1206XX through 0119XX)
1999 (NS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth
Voyager/Grand Voyager
NOTE:
This recall applies only to the above vehicles built from December 6, 1998 through January 19,
1999 (MDH 1206XX through 0119XX)
1999 (WJ) Jeep Grand Cherokee
NOTE:
This recall applies only to the above vehicles built from December 6, 1998 through January 19,
1999 (MDH 1206XX through 0119XX)
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.
Subject
One or both of the front seat belt retractor assemblies on about 150,000 of the above vehicles may
not comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 209. An
improperly manufactured internal lever may not lock the seat belt retractor. This could allow
increased risk of injury to a front seat occupant in certain accident conditions.
Repair
The front seat belt retractor assembly(s) must be replaced.
Parts Information
No parts will be distributed initially for this recall. Dealers should determine which Seat Belt
Retractor package is required for each vehicle at the time appointments are scheduled to assure
that the correct parts are available when the customer arrives. Each package contains a right and a
left front seat belt retractor (except as noted) . The retractor package for the vehicle to be serviced
may be determined by:
^ Using the part code in the third column of the VIN list along with the table (involved dealers);
^ Using the VIN and part number list electronically transmitted to DIAL System Function 53
(involved dealers); or
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Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt
Retractor Replacement > Page 5765
^ Entering the VIN into the DIAL VIP System (sales code information) along with the table (all
dealers) shown.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Use one of the labor operation numbers and time allowances shown.
Parts Return
Not required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt
Retractor Replacement > Page 5766
Dealer Notification and Vehicle List
All dealers will receive a copy of this dealer recall notification letter by firs class mail. Two additional
copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the
near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the
same street address) will receive a list of their involved vehicles. The vehicle list is arranged in
Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed.
The lists are for dealer reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer injury as
needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD978".
Owner Notification and Service Scheduling
All involved vehicle owners known to Daimlerchrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
Daimlerchrysler Mobile Service approved repair.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
AB Vans/Wagons
IMPORTANT: Ram Vans/Wagons equipped with a sliding door require right (passenger side) front
seat belt retractor assembly replacement only.
1. Open the passenger side doors.
2. Using a small flat blade, pry the turning loop cover open.
3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster.
4. Remove the retractor/seat belt lower anchor bolt from the front seat riser.
5. Remove and discard the retractor assembly.
6. Install the new retractor assembly.
7. Install the retractor/seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
8. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
9. Close the turning loop cover.
10. For vehicles equipped with dual hinged side doors, repeat Steps 1-9 for the driver's side of the
vehicle.
AN Trucks
IMPORTANT:
Dakota trucks require left (driver side) front seat belt retractor assembly replacement only.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt
Retractor Replacement > Page 5767
1. Open the driver's side door.
2. Remove the driver's door sill plate.
3. For Club Cab trucks, remove the cab back trim panel.
4. Using a small flat blade, pry the front seat belt turning loop cover open.
5. Remove the front seat belt turning loop attaching bolt and disconnect the turning loop from the
height adjuster.
6. For Club Cab trucks, pry the rear seat belt turning loop cover open using a small flat blade.
7. For Club Cab trucks, remove the rear seat belt turning loop attaching bolt and disconnect the
turning loop from the height adjuster.
8. Remove the quarter (B-Pillar) trim panel.
9. Remove the lower seat belt anchor bolt.
10. Remove the anchor bolt that attaches the retractor to the B-pillar.
11. Disconnect the retractor electrical connector (if equipped).
12. Remove and discard the retractor assembly.
13. Install the new retractor assembly.
14. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm).
15. Connect the retractor electrical connector (if equipped).
16. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm).
17. Install the quarter (B-pillar) trim panel.
18. For Club Cab trucks, install the rear seat belt turning loop anchor bolt. Tighten the bolt to 30
ft-lbs (41 Nm).
19. Install the front seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm).
20. Close the turning loop cover(s).
21. For Club Cab trucks, install the cab back trim panel.
22. Install the door sill plate.
DN Vehicles
1. Open the driver's door.
2. Using a small flat blade, pry the turning loop cover open.
3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster.
4. Remove the lower seat belt anchor bolt from the driver's seat.
5. Remove the driver's door sill plate.
6. Remove the upper B-Pillar trim panel.
7. Remove the lower B-Pillar trim panel.
8. Disconnect the retractor electrical connector.
9. Remove the anchor bolt that attaches the retractor to the B-pillar.
10. Remove and discard the retractor assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt
Retractor Replacement > Page 5768
11. Remove the anti-rotation tab from the new retractor assembly and then install the new retractor
assembly.
12. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
13. Connect the retractor electrical connector.
14. Install the lower B-pillar trim panel.
15. Install the upper B-pillar trim panel.
16. Install the driver's door sill plate.
17. Install the lower seat belt anchor bolt (Figure 3). Tighten the bolt to 17 ft-lbs (23 Nm)
18. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
19. Close the turning loop cover.
20. Repeat Steps 1-19 for the passenger side of the vehicle.
LH Vehicles
1. Using a small flat blade, pry the turning loop cover open.
2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster.
3. Remove the seat belt/retractor lower anchor bolt.
4. Remove the upper B-Pillar trim panel.
5. Remove the lower B-Pillar trim panel.
6. Remove and discard the retractor assembly.
7. Install the new retractor assembly.
8. Install the lower B-pillar trim panel.
9. Install the upper B-pillar trim panel.
10. Install the seat belt/retractor lower anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
11. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
12. Close the turning loop cover.
13. Repeat Steps 1-12 for the other side of the vehicle.
WJ Vehicles
1. Open the driver's door.
2. Using a small flat blade, pry the turning loop cover open.
3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster.
4. Remove the lower seat belt anchor bolt.
5. Remove the driver's door sill plate.
6. Remove the lower B-Pillar trim panel.
7. Remove and discard the retractor assembly.
8. Install the new retractor assembly.
9. Install the lower B-pillar trim panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 978 > Aug > 01 > Recall - Seat Belt
Retractor Replacement > Page 5769
10. Install the driver's door sill plate.
11. Install the lower seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
12. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
13. Close the turning loop cover.
14. Repeat Steps 1-13 for the passenger side of the vehicle.
NS Minivans
IMPORTANT:
Town & Country minivans equipped with a taupe-colored leather interior require left (driver side)
front seat belt retractor assembly replacement only.
1. Using a small flat blade, pry the turning loop cover open.
2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster.
3. Remove the upper B-Pillar trim panel.
4. Remove the seat belt floor anchor bolt.
5. Remove the lower B-Pillar trim panel. (On three door models, remove the upper bolster from the
left quarter trim panel, remove the five screws across the top and three screws at the front of the
trim panel and then pull the front of the quarter trim panel back far enough to access the retractor
assembly.)
6. Remove the anchor bolt that attaches the retractor to the B-pillar.
7. Disconnect the retractor electrical connector, if equipped, and then remove and discard the
retractor assembly.
8. Connect the retractor electrical connector, if equipped, and then install the new retractor
assembly.
9. Install the retractor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
10. Install the lower B-pillar trim panel (or left quarter trim panel on three door models).
11. Install the seat belt floor anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm). Make sure that the
floor anchor is properly oriented (30 outboard).
12. Install the upper B-pillar trim panel.
13. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 Nm)
14. Close the turning loop cover.
15. Repeat Steps 1-14 for the other side of the vehicle if necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > NHTSA01V119000 > Apr > 01 >
Recall 01V119000: Seat Belt Retractor
Seat Belt Retractor: All Technical Service Bulletins Recall 01V119000: Seat Belt Retractor
Vehicle Description: Certain van, wagon, pickup trucks, passenger and sport utility vehicles, fail to
comply with requirements of FMVSS No. 209, "Seat Belt Assemblies." The front seat belt retractor
may not comply with the requirements of the standard.
If the retractor does not work properly, it will not adequately protect occupants in the event of a
crash.
Dealers will replace the seat belt retractor. DaimlerChrysler has not yet provided NHTSA with an
owner notification schedule for this campaign.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED
NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS,
PARTS, AND 2001 MODEL YEAR PROCEDURES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS.
SUBJECT: Airbag On-Off Switches
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Convertible
1994 - **2001** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
**2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - **2001** (PL) Neon
1997 (PR) Prowler
**2001 (PT) PT Cruiser**
**2001** (RS) Town & Country/Caravan/Voyager
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5779
1996 - 1997 (SR) Viper
**2001 - 2002 (ST) Sebring Coupe/Stratus Coupe**
1997 - 2001** (TJ) Wrangler
1999 - **2001** (WJ) Grand Cherokee
1997 - **2001** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
NOTE:
**SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE
OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS
DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.**
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated) and
a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule,
consumers will be authorized for on-off switches by claiming they meet any of several criteria.
Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA
authorization letter. For more information concerning the authorization process and/or the
authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you
(dealer) to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
NOTE:
FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001
CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS
REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG
SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE
CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE
AIRBAG KIT.
**FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS,
AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N
05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE
NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.**
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Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5780
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5781
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5782
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5783
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5784
PARTS REQUIRED:
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have~
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on
your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
POLICY: Information Only
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Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5785
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch
Availibility
NO: 08-17-98 Rev. C
GROUP: Electrical
DATE: Dec. 30, 1998
SUBJECT: Airbag On-Off Switches
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED
SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL
MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
**1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan**
1995 - **1999** (AB) Ram Van/Wagon
**1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon**
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/Convertible
1994 -**1999** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan/Voyager
**1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue**
1994 - **1999** (BR) Ram Pickup
**1995 - 1996 (B7) Stealth**
1998 - **1999** (DN) Durango
**1995 - 1999 (FJ) Avenger/Sebring/Talon**
1995 - **1999** (JA) Breeze/Cirrus/Stratus
1996 - **1999** (JX) Sebring Convertible
1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - **1999** (NS) Town & Country/Caravan/ Voyager
1995 - **1999** (PL) Neon
1996 - 1997 (SR) Viper
1997 - **1999** (TJ) Wrangler
1997 - **1999** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. Other applicable passenger vehicles will be announced as soon as the switches are
available. The switches are packaged in a kit containing all necessary parts (except as indicated)
and a detailed instruction sheet.
Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for
on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be
installed without the vehicle owner presenting the NHTSA authorization letter. For more information
concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety
Hotline at 1-800-424-9393.
We encourage you (dealer) to install these switches when the customer is interested in doing so
and has the necessary NHTSA authorization.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5786
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5787
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5788
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5789
PARTS REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5790
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have.
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for
your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 5791
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations
Impact Sensor: Locations
Instrument Panel Supports
The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Page 5795
Impact Sensor: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams
Seat Belt Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and
Operation
Antenna: Description and Operation
SYSTEM OPERATION
All models use a fixed-length stainless steel rod-type antenna mast, installed at the right front
fender of the vehicle. The antenna mast is connected to the center wire of the coaxial antenna
cable, and is not grounded to any part of the vehicle.
To eliminate static, the antenna base must have a good ground. The coaxial antenna cable shield
(the outer wire mesh of the cable) is grounded to the antenna base and the radio chassis.
The antenna coaxial cable has an additional disconnect, located near the right end of the
instrument panel. This additional disconnect allows the instrument panel assembly to be removed
and installed without removing the radio.
The factory-installed Electronically Tuned Radios (ETRs) automatically compensate for radio
antenna trim. Therefore, no antenna trimmer adjustment is required or possible when replacing the
receiver or the antenna.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and
Operation > Page 5803
Antenna: Testing and Inspection
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERV1CE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
Antenna Test Points
The ohmmeter test lead connections for each test are shown.
TEST 1 Test 1 determines of the antenna mast is insulated from the base. Proceed as follows: 1.
Unplug the antenna coaxial cable from the radio chassis and isolate. Remove the antenna mast. 2.
Connect an ohmmeter test lead to the inside center of the antenna base. Connect the other test
lead to a metallic portion on the outside of the
antenna base. Check for continuity.
3. There should be no continuity. If continuity is found, replace the faulty or damaged antenna base
and cable assembly.
TEST 2 Test 2 checks the antenna for an open circuit as follows: 1. Unplug the antenna coaxial
cable connector from the radio chassis. Remove the antenna mast. The painted mast prevents
measurement directly
through the mast.
2. Connect an ohmmeter test lead to the inside center of the antenna base. Connect the other test
lead to the center pin of the antenna coaxial cable
connector.
3. Continuity should exist the ohmmeter should only register a fraction of an ohm). High or infinite
resistance indicates damage to the base and cable
assembly. Replace the faulty base and cable if required.
TEST 3 Test 3 checks the condition of the ground between the antenna base and the vehicle body
as follows: 1. Connect one ohmmeter test lead to the fender on an exposed metal area paint and
e-coat must be penetrated to obtain continuity). Connect the
other test lead to the outer crimp on the antenna coaxial cable connector.
2. The resistance should be less than (1) ohm. 3. If the resistance is more than (1) ohm, clean
and/or tighten the antenna base to the fender mounting hardware.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and
Repair > Antenna Extension Cable
Antenna: Service and Repair Antenna Extension Cable
REMOVAL
1. Remove glove box.
Antenna Cable
2. Disconnect extension cable end from antenna cable end. 3. Disconnect cable hanger clip from
HVAC unit. 4. Remove radio as necessary to gain access to extension cable. 5. Disconnect
extension cable from back of radio. 6. Remove extension cable from vehicle.
INSTALLATION
For installation reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and
Repair > Antenna Extension Cable > Page 5806
Antenna: Service and Repair Antenna Mast and Cable Lead
REMOVAL
1. Remove glove box from instrument panel, refer to Instrument Panel and Systems for proper
procedures.
Antenna Cable
2. Disconnect antenna cable connector from extension cable. 3. Remove right kick trim panel. 4.
Remove fender splash shield. 5. Disengage rubber grommet insulator from door hinge pillar. 6. Pull
antenna cable through hinge pillar into open between door hinges. 7. Hoist and support vehicle on
safety stands. 8. Remove front wheel. 9. Remove front wheelhouse splash shield.
Antenna Mast
10. Remove antenna mast from antenna base.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and
Repair > Antenna Extension Cable > Page 5807
Antenna Cap Nut Remove/Install - Typical
11. Remove plastic cap from the cap nut. Using cap nut tool, remove cap nut holding antenna base
to front fender. 12. Remove antenna base from under front fender.
INSTALLATION
For installation, reverse the above procedure. Torque antenna base retaining nut to 28-32 in.lbs.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch,
Antitheft > Component Information > Diagrams
Arm/Disarm Switch: Diagrams
Driver Door Arm/Disarm Switch
Passenger Door Arm/Disarm Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch
(For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch
Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Open the front door.
Front Door Ajar Switch
3. Remove the screw holding the door ajar switch to the door B-pillar. 4. Remove the door ajar
switch from the B-pillar. 5. Disconnect the wire connector from the back of the ajar switch and
remove the switch.
INSTALLATION
For installation reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch
(For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch > Page 5816
Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Release the sliding door latch and allow
back of the door to pop open.
Sliding Door Ajar Switch
3. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar
switch from quarter panel opening. 4. Disconnect the wire connector from the back of the ajar
switch. 5. Remove the sliding door ajar switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch
(For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood.
Negative Battery Cable
2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry
trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire
connector and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Diagrams
Remote Keyless Entry (RKE) Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Diagrams > Page 5824
Keyless Entry Module: Adjustments
The content of this article reflects the changes called out by TSB 26-09-99.
PROGRAMMING RKE MODULE
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the
transmitter at the same time. Then press any one of
the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of
the transmitter has been completed and was successful.
7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8.
Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the
ignition OFF. A single chime will sound to verify
that the RKE module will no longer accept additional Vehicle Access Code(s).
9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF
position and verify RKE system operation using each
key fob.
NOTE: Only the two key fob transmitters that have been programmed to the memory seat and
mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will
require programming.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Diagrams > Page 5825
Keyless Entry Module: Service and Repair
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer
to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws
holding RKE module to instrument panel.
RKE Module
4. Disconnect wire connector from RKE module.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Programming Connector > Component Information > Locations
Remote Keyless Entry (RKE) Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Specifications
Keyless Entry Transmitter Battery: Specifications
The batteries can be removed without special tools and are readily available at local retail stores.
The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years.
CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary.
Hands must be clean and dry.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch >
Component Information > Service and Repair
Lock Cylinder Switch: Service and Repair
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel and sound
pad. 3. Close the door window. 4. Disconnect the door key cylinder switch wire connector from the
door harness and wiring clip from the impact beam. 5. Remove the front door outside handle from
the door.
Door Lock Cylinder Switch
6. Disengage the lock tab holding switch to the back of the lock cylinder. 7. Remove the switch
from the door handle.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate
Sensor/Switch (For Alarm) > Component Information > Diagrams
Trunk/Liftgate Sensor/Switch (For Alarm): Diagrams
Hood Ajar Switch
Liftgate Arm/Disarm Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate
Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate latch from the vehicle.
3. Disconnect the wire connector from the liftgate ajar switch.
Liftgate Ajar Switch
4. Remove the screw holding the ajar switch to the liftgate latch and remove the switch.
INSTALLATION
For installation, Reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate
Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch > Page
5841
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Key Cylinder Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate trim panel. 3.
Disconnect the liftgate key cylinder switch wire connector from the liftgate harness and clip from the
liftgate inner panel. 4. Remove the liftgate outside handle.
Liftgate Cylinder Lock Switch
5. Disconnect the lock tab holding the switch to the back of lock cylinder and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations
Driver/Vehicle Information Display: Locations
Information Center
Information Center
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions
Driver/Vehicle Information Display: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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Information > Diagrams > Diagram Information and Instructions > Page 5847
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 5848
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 5849
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 5850
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 5851
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Information > Diagrams > Diagram Information and Instructions > Page 5852
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 5853
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Information > Diagrams > Diagram Information and Instructions > Page 5854
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Information > Diagrams > Diagram Information and Instructions > Page 5855
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Information > Diagrams > Diagram Information and Instructions > Page 5856
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Information > Diagrams > Diagram Information and Instructions > Page 5857
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Information > Diagrams > Diagram Information and Instructions > Page 5858
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Information > Diagrams > Diagram Information and Instructions > Page 5859
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
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Driver/Vehicle Information Display: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
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Driver/Vehicle Information Display: Connector Views
Connector Pin Identification
Message Center
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Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
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Driver/Vehicle Information Display: Electrical Diagrams
Information Center
Wiring Diagrams
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Message Center -- Sheet 8w-46-2
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Message Center -- Sheet 8w-46-3
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Message Center -- Sheet 8w-46-4
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Message Center -- Sheet 8w-46-5
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Message Center -- Sheet 8w-46-6
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
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Driver/Vehicle Information Display: Description and Operation
The Overhead Console consists of a Compass/Mini-Trip Computer (CMTC), Universal Transmitter
and Reading/Dome lamps.
The CMTC consists of an electronic control module with a vacuum fluorescent display (VFD) and
function switches. The CMTC displays compass heading, trip computer with traveler messages,
and exterior temperature features. For more information on CMTC features, see Instrument
Panel/Compass, Outside Temperature Display, and Lighting/Dome Lamp.
The Universal Transmitter replaces the hand held remote controls that open the garage door,
motorized gates, or home lighting in/outside the home. This device memorizes the activator codes
for up to three remote controlled devices. It triggers those devices at the push of a button, located
in a unit permanently mounted in your overhead console (if equipped).
The transmitter operates off the vehicle's battery and charging system; no batteries are needed.
The Universal Transmitter incorporates a Rolling Code technology (random digital code signals
from the remote transmitter) within the transmitter module. This is done so as an added security
measure.
Features of the Universal Transmitter are:
^ Can be used with most other Radio Frequency (RF) activated devices.
^ Individual channels can be trained.
^ Stores transmitter data in permanent memory- retraining is not required even if the battery dies or
is disconnected.
To operate, simply press the appropriate button on the Universal Transmitter. The red LED will light
up while the signal is being transmitted.
NOTE: For security reasons, you are able to erase the trained frequencies.
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Driver/Vehicle Information Display: Service and Repair Universal Transmitter Training and Erasing
Universal Transmitter
TRAINING
1. Turn off the engine. 2. Erase the factory test codes by pressing the two outside buttons. Release
the buttons when the red light begins to flash (about 20 seconds). 3. Choose one of the three
buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and
push the buttons on both
transmitters. The red light on the universal transmitter will begin to flash slowly.
4. When the red light on the universal transmitter begins to flash rapidly (this may take as long as
60 seconds), release both buttons. Your universal
transmitter is now "trained". To train the other buttons, repeat Step 3 and Step 4. Be sure to keep
your hand-held transmitter in case you need to retrain the universal transmitter.
ERASING
To erase the universal transmitter codes, simply hold down the two outside buttons until the red
LED begins to flash.
NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL
programmed codes.
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Driver/Vehicle Information Display: Service and Repair Replacement
Universal Transmitter
REMOVAL
The Universal Transmitter is serviced with the transmitter bin door, in the overhead console.
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Open transmitter bin door in rear of
overhead console. 3. Gently pull towards rear of vehicle, releasing transmitter bin door. 4.
Disconnect harness connector from Universal Transmitter and remove bin door from vehicle.
INSTALLATION
For installation, reverse the above procedures. The Universal Transmitter will need to be retrained.
Refer to SERVICE PROCEDURES.
Message Center
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove A-pillar trim panel. 3. Remove
instrument panel top cover. Refer to Instrument Panel Top Cover Replacement. 4. Disconnect the
wire connector from back of message center 5. Remove screws holding message center to
instrument panel top cover.
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6. Remove message center from instrument panel top cover.
INSTALLATION
1. Place message center in position on top cover. 2. Install screws to hold message center to
instrument panel top cover. 3. Connect wire connector into back of message center. 4. Install
instrument panel top cover. 5. Install A-pillar trim.
Message Center Lamp
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer
to Instrument Panel Top Cover Replacement.
Message Center Lamp Location
3. Locate the lamp in question. 4. Remove lamp and check lamp. If lamp is good test the power
supply to the lamp.
INSTALLATION
For installation, reverse the above procedures.
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Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
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Garage Door Opener Transmitter: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Diagram Information and Instructions > Page 5894
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Diagram Information and Instructions > Page 5895
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Diagram Information and Instructions > Page 5896
Garage Door Opener Transmitter: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Diagram Information and Instructions > Page 5897
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Diagram Information and Instructions > Page 5898
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Diagram Information and Instructions > Page 5899
Garage Door Opener Transmitter: Electrical Diagrams
Message Center -- Sheet 8w-46-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Diagram Information and Instructions > Page 5900
Message Center -- Sheet 8w-46-3
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Diagram Information and Instructions > Page 5901
Message Center -- Sheet 8w-46-4
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Diagram Information and Instructions > Page 5902
Message Center -- Sheet 8w-46-5
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Diagram Information and Instructions > Page 5903
Message Center -- Sheet 8w-46-6
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Page 5904
Garage Door Opener Transmitter: Description and Operation
The Universal Transmitter replaces the hand held remote controls that open the garage door,
motorized gates, or home lighting in/outside the home. This device memorizes the activator codes
for up to three remote controlled devices. It triggers those devices at the push of a button, located
in a unit permanently mounted in your overhead console (if equipped).
The transmitter operates off the vehicle's battery and charging system; no batteries are needed.
The Universal Transmitter incorporates a Rolling Code technology (random digital code signals
from the remote transmitter) within the transmitter module. This is done so as an added security
measure.
Features of the Universal Transmitter are:
^ Can be used with most other Radio Frequency (RF) activated devices.
^ Individual channels can be trained.
^ Stores transmitter data in permanent memory- retraining is not required even if the battery dies or
is disconnected.
To operate, simply press the appropriate button on the Universal Transmitter. The red LED will light
up while the signal is being transmitted.
NOTE: For security reasons, you are able to erase the trained frequencies.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Diagrams > Page 5905
Garage Door Opener Transmitter: Testing and Inspection
Before proceeding in diagnosis, check the transmitter for battery voltage and a good ground at the
transmitter harness connector.
- The unit may not have been trained correctly, try retraining the transmitter.
- The batteries in the hand-held transmitter may be dead.
- Rotate your hand-held transmitter end-over-end and train again.
For best results, place the end opposite from the battery compartment against the universal
transmitter while training.
- The frequency of the hand-held transmitter may not be in the desired frequencies between
286MHz and 399MHz set by FCC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Service and Repair > Universal Transmitter Training and Erasing
Garage Door Opener Transmitter: Service and Repair Universal Transmitter Training and Erasing
Universal Transmitter
TRAINING
1. Turn off the engine. 2. Erase the factory test codes by pressing the two outside buttons. Release
the buttons when the red light begins to flash (about 20 seconds). 3. Choose one of the three
buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and
push the buttons on both
transmitters. The red light on the universal transmitter will begin to flash slowly.
4. When the red light on the universal transmitter begins to flash rapidly (this may take as long as
60 seconds), release both buttons. Your universal
transmitter is now "trained". To train the other buttons, repeat Step 3 and Step 4. Be sure to keep
your hand-held transmitter in case you need to retrain the universal transmitter.
ERASING
To erase the universal transmitter codes, simply hold down the two outside buttons until the red
LED begins to flash.
NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL
programmed codes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Service and Repair > Universal Transmitter Training and Erasing > Page 5908
Garage Door Opener Transmitter: Service and Repair Replacement
Universal Transmitter
REMOVAL
The Universal Transmitter is serviced with the transmitter bin door, in the overhead console.
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Open transmitter bin door in rear of
overhead console. 3. Gently pull towards rear of vehicle, releasing transmitter bin door. 4.
Disconnect harness connector from Universal Transmitter and remove bin door from vehicle.
INSTALLATION
For installation, reverse the above procedures. The Universal Transmitter will need to be retrained.
Refer to SERVICE PROCEDURES.
Message Center
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove A-pillar trim panel. 3. Remove
instrument panel top cover. Refer to Instrument Panel Top Cover Replacement. 4. Disconnect the
wire connector from back of message center 5. Remove screws holding message center to
instrument panel top cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Service and Repair > Universal Transmitter Training and Erasing > Page 5909
6. Remove message center from instrument panel top cover.
INSTALLATION
1. Place message center in position on top cover. 2. Install screws to hold message center to
instrument panel top cover. 3. Connect wire connector into back of message center. 4. Install
instrument panel top cover. 5. Install A-pillar trim.
Message Center Lamp
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer
to Instrument Panel Top Cover Replacement.
Message Center Lamp Location
3. Locate the lamp in question. 4. Remove lamp and check lamp. If lamp is good test the power
supply to the lamp.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Technical Service Bulletins > Customer Interest for Amplifier: > 08-15-00 > Apr > 00 >
Instrument Panel Speaker - Intermittent Operation/Static
Amplifier: Customer Interest Instrument Panel Speaker - Intermittent Operation/Static
NUMBER: 08-15-00
GROUP: Electrical
DATE: Apr.21,2000
SUBJECT: Intermittent Instrument Panel Speaker Operation/Static
MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager
(International Market)
OVERVIEW: This bulletin involves installing a new speaker/amplifier assembly
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE INFINITY(R) SOUND
SYSTEM SALES CODES (RCE, RBN, AND RAZ).
SYMPTOM/CONDITION: Intermittent operation/static may occur in front I/P speakers.
DIAGNOSIS:
1. Turn the ignition key to the RUN position.
2. Turn the radio ON.
3. Insert a known good quality CD or Tape into the sound system.
4. Increase and decrease the volume while listening for static.
5. Move the fade control fully forward, and adjust the speaker balance control from left to right while
listening for static and/or intermittent operation of the speakers.
6. Increase and decrease the volume while listening for static and/or intermittent operation of the
speakers.
7. If the static/intermittent operation is present and is coming from the same speaker(s) even if the
fade and speaker R/L controls are changed and the static intermittent operation does not change
with volume, the static may be due to a failed speaker amplifier. Perform the following Repair
Procedure to replace the speaker amplifier.
8. If static/intermittent operation is present and the static/intermittent operation changes from
speaker to speaker as the fade and speaker R/L controls are operated, the static/intermittent
operation may be due to a malfunctioning radio and this bulletin does not apply.
PARTS REQUIRED:
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
NOTE: THE RIGHT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH RIGHT
FRONT DOOR AND RIGHT INSTRUMENT PANEL (I/P) SPEAKERS. IF THE STATIC OR THE
INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE RIGHT I/P SPEAKER OF
THE VEHICLE, REPLACE THE RIGHT FRONT DOOR SPEAKER. LIKEWISE, THE LEFT FRONT
DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH LEFT FRONT DOOR AND LEFT I/P
SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER
OCCURS IN THE LEFT I/P SPEAKER OF THE VEHICLE, REPLACE THE LEFT FRONT DOOR
SPEAKER. DO NOT REPLACE THE RIGHT OR LEFT I/P SPEAKERS.
1. Remove the front door speaker(s) containing the malfunctioning amplifier. Refer to page 8F-1O
of the 2000 Town & Country, Caravan and
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Technical Service Bulletins > Customer Interest for Amplifier: > 08-15-00 > Apr > 00 >
Instrument Panel Speaker - Intermittent Operation/Static > Page 5919
Voyager Service Manual (Publication No.81-370-0005) for information regarding front door speaker
removal and installation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: 61 - Intermittent Operation
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Amplifier: > 08-15-00 >
Apr > 00 > Instrument Panel Speaker - Intermittent Operation/Static
Amplifier: All Technical Service Bulletins Instrument Panel Speaker - Intermittent Operation/Static
NUMBER: 08-15-00
GROUP: Electrical
DATE: Apr.21,2000
SUBJECT: Intermittent Instrument Panel Speaker Operation/Static
MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager
(International Market)
OVERVIEW: This bulletin involves installing a new speaker/amplifier assembly
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE INFINITY(R) SOUND
SYSTEM SALES CODES (RCE, RBN, AND RAZ).
SYMPTOM/CONDITION: Intermittent operation/static may occur in front I/P speakers.
DIAGNOSIS:
1. Turn the ignition key to the RUN position.
2. Turn the radio ON.
3. Insert a known good quality CD or Tape into the sound system.
4. Increase and decrease the volume while listening for static.
5. Move the fade control fully forward, and adjust the speaker balance control from left to right while
listening for static and/or intermittent operation of the speakers.
6. Increase and decrease the volume while listening for static and/or intermittent operation of the
speakers.
7. If the static/intermittent operation is present and is coming from the same speaker(s) even if the
fade and speaker R/L controls are changed and the static intermittent operation does not change
with volume, the static may be due to a failed speaker amplifier. Perform the following Repair
Procedure to replace the speaker amplifier.
8. If static/intermittent operation is present and the static/intermittent operation changes from
speaker to speaker as the fade and speaker R/L controls are operated, the static/intermittent
operation may be due to a malfunctioning radio and this bulletin does not apply.
PARTS REQUIRED:
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
NOTE: THE RIGHT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH RIGHT
FRONT DOOR AND RIGHT INSTRUMENT PANEL (I/P) SPEAKERS. IF THE STATIC OR THE
INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE RIGHT I/P SPEAKER OF
THE VEHICLE, REPLACE THE RIGHT FRONT DOOR SPEAKER. LIKEWISE, THE LEFT FRONT
DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH LEFT FRONT DOOR AND LEFT I/P
SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER
OCCURS IN THE LEFT I/P SPEAKER OF THE VEHICLE, REPLACE THE LEFT FRONT DOOR
SPEAKER. DO NOT REPLACE THE RIGHT OR LEFT I/P SPEAKERS.
1. Remove the front door speaker(s) containing the malfunctioning amplifier. Refer to page 8F-1O
of the 2000 Town & Country, Caravan and
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Amplifier: > 08-15-00 >
Apr > 00 > Instrument Panel Speaker - Intermittent Operation/Static > Page 5925
Voyager Service Manual (Publication No.81-370-0005) for information regarding front door speaker
removal and installation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: 61 - Intermittent Operation
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc
Player (CD) > Component Information > Technical Service Bulletins > CD Player - CD Compatibility
Compact Disc Player (CD): Technical Service Bulletins CD Player - CD Compatibility
BULLETIN NUMBER: 08-11-00
GROUP: Electrical
DATE: March 24, 2000
SUBJECT: Recordable Compact Discs Used in Automotive CD players
MODELS: 1989 - 2000 (AB) Ram Van/Wagon 1989 - 2000 (AN) Dakota 1994 - 2000 (BR/BE) Ram
Truck 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GT 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee
1997 - 2000 (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee
DISCUSSION: Some recordable compact disc media, such as CD-R and CD-RW, may not comply
with the standard CD format used in automotive CD players. When these CD's are used,
customers may encounter error messages, skipping, or delaminating of the labels, which can
cause an eject failure. It is important to question whether these kinds of CD media are being used.
When customers encounter these symptoms, check the system with a known playable CD. Explain
that the media may not be compatible with some automotive CD players. Replacing or exchanging
the CD player will not address these issues.
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc
Player (CD) > Component Information > Technical Service Bulletins > Page 5930
Compact Disc Player (CD): Service and Repair
REMOVAL
1. Remove HVAC switch bezel, refer to Instrument Panel and Systems for proper procedure.
Radio
2. Remove screws holding radio to instrument panel.
Radio Connectors
3. Pull radio rearward to gain access to back of radio. 4. Remove bolt holding ground strap to back
of radio. 5. Disconnect antenna cable from back of radio. 6. Disconnect the wire connectors from
back of radio. 7. Remove radio from vehicle.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise
Radio/Stereo Noise Filter: Customer Interest Radio - Poor AM Reception/Ignition Noise
NUMBER: 08-45-99
GROUP: Electrical
DATE: Dec. 31, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2,
1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO.
81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
SUBJECT: AM Radio Reception
OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module,
adding a jumper harness, ground strap and tie-strap.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition
noise (static that varies with engine RPM) on low power/distant stations.
DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that
varies with engine RPM is heard check the antenna connection, the antenna ground, the ground
straps across the right side motor mount, and from the back of the engine to the dash panel. If
these check ok but the static condition still exists, perform the Repair Procedure.
PARTS REQUIRED:
1 05016107AA Shield Package
Contents Of Shield Package:
1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts
1 05016105AA Wiring Repair Package 1996-1998
1 05016106AA Wiring Repair Package 1999-2000
Contents of Wiring Packages:
1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor,
1-Capacitor Mounting Bolt
REPAIR PROCEDURE:
1. Disconnect the negative battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5940
Fig. 1
2. Disconnect the electrical connector from the ignition coil module, Figure 1.
3. Remove the ignition coil module bottom-forward mounting bolt and discard.
Fig. 2
4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque
the screw to 10-15 Nm (85-125 in. lbs.)
5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then
connect the jumper harness between the ignition coil module and the powertrain harness
connector, Figure 2.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5941
Fig. 3
Fig. 3A
6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of
the powertrain harness (see fig. 3 or fig. 3a).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5942
Fig. 4
7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4.
8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs.
Torque studs to 10-15 Nm (85-125 in. lbs.)
Fig. 5
9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure
5. Torque the nuts to 10-15 Nm (85-125 in. lbs.).
10. Turn the ignition switch to the Unlock position so the steering wheel can rotate.
11. Raise vehicle. Then turn the front wheels to the left.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5943
Fig. 6
12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut
assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap
eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching
bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse
panel/frame to 11 Nm (95 in. lbs.), Figure 6.
13. Center the front wheels and lower the vehicle.
14. Connect the negative battery cable and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-12-02-91 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise
Radio/Stereo Noise Filter: All Technical Service Bulletins Radio - Poor AM Reception/Ignition Noise
NUMBER: 08-45-99
GROUP: Electrical
DATE: Dec. 31, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2,
1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO.
81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
SUBJECT: AM Radio Reception
OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module,
adding a jumper harness, ground strap and tie-strap.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition
noise (static that varies with engine RPM) on low power/distant stations.
DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that
varies with engine RPM is heard check the antenna connection, the antenna ground, the ground
straps across the right side motor mount, and from the back of the engine to the dash panel. If
these check ok but the static condition still exists, perform the Repair Procedure.
PARTS REQUIRED:
1 05016107AA Shield Package
Contents Of Shield Package:
1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts
1 05016105AA Wiring Repair Package 1996-1998
1 05016106AA Wiring Repair Package 1999-2000
Contents of Wiring Packages:
1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor,
1-Capacitor Mounting Bolt
REPAIR PROCEDURE:
1. Disconnect the negative battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5949
Fig. 1
2. Disconnect the electrical connector from the ignition coil module, Figure 1.
3. Remove the ignition coil module bottom-forward mounting bolt and discard.
Fig. 2
4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque
the screw to 10-15 Nm (85-125 in. lbs.)
5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then
connect the jumper harness between the ignition coil module and the powertrain harness
connector, Figure 2.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5950
Fig. 3
Fig. 3A
6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of
the powertrain harness (see fig. 3 or fig. 3a).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5951
Fig. 4
7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4.
8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs.
Torque studs to 10-15 Nm (85-125 in. lbs.)
Fig. 5
9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure
5. Torque the nuts to 10-15 Nm (85-125 in. lbs.).
10. Turn the ignition switch to the Unlock position so the steering wheel can rotate.
11. Raise vehicle. Then turn the front wheels to the left.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 5952
Fig. 6
12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut
assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap
eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching
bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse
panel/frame to 11 Nm (95 in. lbs.), Figure 6.
13. Center the front wheels and lower the vehicle.
14. Connect the negative battery cable and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-12-02-91 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Description and Operation
Remote Switch: Description and Operation
SYSTEM OPERATION
Remote Radio Switches
Remote Radio Switch Operational View
A remote radio control switch option is available on LXI models sold in North America with the
AM/FM/ cassette/5-band graphic equalizer with CD changer control feature (RBN sales code), or
the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two
rocker-type switches are mounted on the back (instrument panel side) of the steering wheel
spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset
station advance functions. The switch on the right spoke is the volume control switch and has
volume up, and volume down functions.
These switches are resistor multiplexed units that are hard-wired to the Body Control Module
(BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision
Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data
bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For
more information on the operation of the remote radio switch controls, refer to the owner's manual
in the vehicle glove box.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 5956
Remote Switch: Testing and Inspection
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system
capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the
steering wheel.
Remote Radio Switches
3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test
table.
REMOTE RADIO SWITCH TEST Switch position = Resistance Volume Up = 7320 Ohms Volume
Down = 1210 Ohms Seek Up = 4530 Ohms Seek Down = 2050 Ohms Pre-set station advance =
10 Ohms
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right"/Left remote radio switch orientation is with the steering wheel installed, and driver in
drivers seat.
4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check
for continuity between the ground circuit cavity of the switch wire harness connector and a good
ground. There should be continuity If OK,
go to Step 6. If not OK, repair the open circuit as required.
6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check
for continuity between the radio control circuit
cavity of the remote radio switch wire harness connector and a good ground. There should be no
continuity If OK, go to Step 7. If not OK, repair the short circuit as required.
7. Check for continuity between the radio control circuit cavities of the remote radio switch wire
harness connector and the BCM wire harness
connector. There should be continuity If OK, refer to the proper Diagnostic Procedures to test the
BCM and the CCD data bus. If not OK, repair the open circuit as required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 5957
Remote Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system
capacitor to discharge before further service. 2. From the underside of the steering wheel, remove
the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the airbag
module away from the steering wheel far enough to access the wire harness connectors on the
back of the airbag module. 4. Unplug the airbag module and horn switch wire harness connectors
from the back of the airbag module. 5. Remove the driver side airbag module from the vehicle. 6.
Remove the steering wheel from the steering column. 7. Unplug the wire harness connector from
the remote radio switch(s). 8. Remove three screws securing steering wheel rear cover. 9. Remove
the remote radio switch from the steering wheel by depressing tabs on each side of switch.
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right/left remote radio switch orientation is with the steering wheel installed, and driver in
drivers seat.
INSTALLATION
For installation, reverse the above procedure. The switches can only be installed one way. Be
careful to index them correctly before pressing them into place.
Tighten the airbag module mounting screws to 10.2 Nm (90 in. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 08-15-00 > Apr > 00 > Instrument
Panel Speaker - Intermittent Operation/Static
Speaker: Customer Interest Instrument Panel Speaker - Intermittent Operation/Static
NUMBER: 08-15-00
GROUP: Electrical
DATE: Apr.21,2000
SUBJECT: Intermittent Instrument Panel Speaker Operation/Static
MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager
(International Market)
OVERVIEW: This bulletin involves installing a new speaker/amplifier assembly
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE INFINITY(R) SOUND
SYSTEM SALES CODES (RCE, RBN, AND RAZ).
SYMPTOM/CONDITION: Intermittent operation/static may occur in front I/P speakers.
DIAGNOSIS:
1. Turn the ignition key to the RUN position.
2. Turn the radio ON.
3. Insert a known good quality CD or Tape into the sound system.
4. Increase and decrease the volume while listening for static.
5. Move the fade control fully forward, and adjust the speaker balance control from left to right while
listening for static and/or intermittent operation of the speakers.
6. Increase and decrease the volume while listening for static and/or intermittent operation of the
speakers.
7. If the static/intermittent operation is present and is coming from the same speaker(s) even if the
fade and speaker R/L controls are changed and the static intermittent operation does not change
with volume, the static may be due to a failed speaker amplifier. Perform the following Repair
Procedure to replace the speaker amplifier.
8. If static/intermittent operation is present and the static/intermittent operation changes from
speaker to speaker as the fade and speaker R/L controls are operated, the static/intermittent
operation may be due to a malfunctioning radio and this bulletin does not apply.
PARTS REQUIRED:
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
NOTE: THE RIGHT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH RIGHT
FRONT DOOR AND RIGHT INSTRUMENT PANEL (I/P) SPEAKERS. IF THE STATIC OR THE
INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE RIGHT I/P SPEAKER OF
THE VEHICLE, REPLACE THE RIGHT FRONT DOOR SPEAKER. LIKEWISE, THE LEFT FRONT
DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH LEFT FRONT DOOR AND LEFT I/P
SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER
OCCURS IN THE LEFT I/P SPEAKER OF THE VEHICLE, REPLACE THE LEFT FRONT DOOR
SPEAKER. DO NOT REPLACE THE RIGHT OR LEFT I/P SPEAKERS.
1. Remove the front door speaker(s) containing the malfunctioning amplifier. Refer to page 8F-1O
of the 2000 Town & Country, Caravan and
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 08-15-00 > Apr > 00 > Instrument
Panel Speaker - Intermittent Operation/Static > Page 5966
Voyager Service Manual (Publication No.81-370-0005) for information regarding front door speaker
removal and installation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: 61 - Intermittent Operation
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 08-15-00 > Apr > 00 >
Instrument Panel Speaker - Intermittent Operation/Static
Speaker: All Technical Service Bulletins Instrument Panel Speaker - Intermittent Operation/Static
NUMBER: 08-15-00
GROUP: Electrical
DATE: Apr.21,2000
SUBJECT: Intermittent Instrument Panel Speaker Operation/Static
MODELS: 1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager
(International Market)
OVERVIEW: This bulletin involves installing a new speaker/amplifier assembly
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE INFINITY(R) SOUND
SYSTEM SALES CODES (RCE, RBN, AND RAZ).
SYMPTOM/CONDITION: Intermittent operation/static may occur in front I/P speakers.
DIAGNOSIS:
1. Turn the ignition key to the RUN position.
2. Turn the radio ON.
3. Insert a known good quality CD or Tape into the sound system.
4. Increase and decrease the volume while listening for static.
5. Move the fade control fully forward, and adjust the speaker balance control from left to right while
listening for static and/or intermittent operation of the speakers.
6. Increase and decrease the volume while listening for static and/or intermittent operation of the
speakers.
7. If the static/intermittent operation is present and is coming from the same speaker(s) even if the
fade and speaker R/L controls are changed and the static intermittent operation does not change
with volume, the static may be due to a failed speaker amplifier. Perform the following Repair
Procedure to replace the speaker amplifier.
8. If static/intermittent operation is present and the static/intermittent operation changes from
speaker to speaker as the fade and speaker R/L controls are operated, the static/intermittent
operation may be due to a malfunctioning radio and this bulletin does not apply.
PARTS REQUIRED:
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
NOTE: THE RIGHT FRONT DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH RIGHT
FRONT DOOR AND RIGHT INSTRUMENT PANEL (I/P) SPEAKERS. IF THE STATIC OR THE
INTERMITTENT OPERATION OF THE SPEAKER OCCURS IN THE RIGHT I/P SPEAKER OF
THE VEHICLE, REPLACE THE RIGHT FRONT DOOR SPEAKER. LIKEWISE, THE LEFT FRONT
DOOR SPEAKER CONTAINS THE AMPLIFIER FOR BOTH LEFT FRONT DOOR AND LEFT I/P
SPEAKERS. IF THE STATIC OR THE INTERMITTENT OPERATION OF THE SPEAKER
OCCURS IN THE LEFT I/P SPEAKER OF THE VEHICLE, REPLACE THE LEFT FRONT DOOR
SPEAKER. DO NOT REPLACE THE RIGHT OR LEFT I/P SPEAKERS.
1. Remove the front door speaker(s) containing the malfunctioning amplifier. Refer to page 8F-1O
of the 2000 Town & Country, Caravan and
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 08-15-00 > Apr > 00 >
Instrument Panel Speaker - Intermittent Operation/Static > Page 5972
Voyager Service Manual (Publication No.81-370-0005) for information regarding front door speaker
removal and installation.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: 61 - Intermittent Operation
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Page 5973
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Page 5974
Speaker: Diagrams
Junction Block
Name Brand Speaker Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Page 5975
Speaker: Description and Operation
SYSTEM OPERATION
Choke - Infinity Speakers If the audio system is cutting in and out at higher volumes, check for
continuity across the choke connector. If no continuity replace the choke assembly The choke is
located on the junction block/body control module.
Name Brand Speaker Relay Relay is located in the junction block. To test relay refer to the Audio
Diagnostic Test Procedures or use a known good relay.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > D-Pillar Speaker
Speaker: Service and Repair D-Pillar Speaker
REMOVAL
1. Remove D-pillar trim panel as necessary to gain access to door speaker. 2. Disconnect wire
connector from speaker.
D-Pillar Speaker
3. Remove by sliding speaker out of bracket by pushing on magnet. The capacitor is wrapped with
foam tape. 4. Remove speaker.
INSTALLATION
For installation reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > D-Pillar Speaker > Page 5978
Speaker: Service and Repair Front Door Speaker
REMOVAL
1. Remove front door trim panel as necessary to gain access to door speaker.
Front Door Speaker
2. Remove screws holding speaker to bracket. 3. Remove speaker from bracket. 4. Disconnect
wire connector from speaker. 5. Remove speaker.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > D-Pillar Speaker > Page 5979
Speaker: Service and Repair Instrument Panel Speaker
REMOVAL
1. Remove instrument panel top cover.
Left Instrument Panel Speaker
Right Instrument Panel Speaker
2. Remove screws holding speaker to instrument panel and remove speaker. 3. Remove anti
rocking finger screw. 4. Disconnect wire connector from speaker. 5. Remove speaker.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > D-Pillar Speaker > Page 5980
Speaker: Service and Repair Quarter Panel Speaker
REMOVAL
1. Remove quarter trim bolster from quarter trim panel.
Quarter Panel Speaker
2. Remove screws holding speaker to inner quarter panel. 3. Separate speaker from quarter panel.
4. Disconnect wire connector from speaker. 5. Remove speaker.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player >
Component Information > Service and Repair
Tape Player: Service and Repair
REMOVAL
1. Remove HVAC switch bezel, refer to Instrument Panel and Systems for proper procedure.
Radio
2. Remove screws holding radio to instrument panel.
Radio Connectors
3. Pull radio rearward to gain access to back of radio. 4. Remove bolt holding ground strap to back
of radio. 5. Disconnect antenna cable from back of radio. 6. Disconnect the wire connectors from
back of radio. 7. Remove radio from vehicle.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams
Remote Keyless Entry (RKE) Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Page 5988
Keyless Entry Module: Adjustments
The content of this article reflects the changes called out by TSB 26-09-99.
PROGRAMMING RKE MODULE
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the
transmitter at the same time. Then press any one of
the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of
the transmitter has been completed and was successful.
7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8.
Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the
ignition OFF. A single chime will sound to verify
that the RKE module will no longer accept additional Vehicle Access Code(s).
9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF
position and verify RKE system operation using each
key fob.
NOTE: Only the two key fob transmitters that have been programmed to the memory seat and
mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will
require programming.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Page 5989
Keyless Entry Module: Service and Repair
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer
to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws
holding RKE module to instrument panel.
RKE Module
4. Disconnect wire connector from RKE module.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams
Arm/Disarm Switch: Diagrams
Driver Door Arm/Disarm Switch
Passenger Door Arm/Disarm Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS
Trigger) Switch
Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Open the front door.
Front Door Ajar Switch
3. Remove the screw holding the door ajar switch to the door B-pillar. 4. Remove the door ajar
switch from the B-pillar. 5. Disconnect the wire connector from the back of the ajar switch and
remove the switch.
INSTALLATION
For installation reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS
Trigger) Switch > Page 5998
Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Release the sliding door latch and allow
back of the door to pop open.
Sliding Door Ajar Switch
3. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar
switch from quarter panel opening. 4. Disconnect the wire connector from the back of the ajar
switch. 5. Remove the sliding door ajar switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood.
Negative Battery Cable
2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry
trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire
connector and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Lock Cylinder Switch > Component Information > Service and Repair
Lock Cylinder Switch: Service and Repair
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel and sound
pad. 3. Close the door window. 4. Disconnect the door key cylinder switch wire connector from the
door harness and wiring clip from the impact beam. 5. Remove the front door outside handle from
the door.
Door Lock Cylinder Switch
6. Disengage the lock tab holding switch to the back of the lock cylinder. 7. Remove the switch
from the door handle.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation
Remote Switch: Description and Operation
SYSTEM OPERATION
Remote Radio Switches
Remote Radio Switch Operational View
A remote radio control switch option is available on LXI models sold in North America with the
AM/FM/ cassette/5-band graphic equalizer with CD changer control feature (RBN sales code), or
the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two
rocker-type switches are mounted on the back (instrument panel side) of the steering wheel
spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset
station advance functions. The switch on the right spoke is the volume control switch and has
volume up, and volume down functions.
These switches are resistor multiplexed units that are hard-wired to the Body Control Module
(BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision
Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data
bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. For
more information on the operation of the remote radio switch controls, refer to the owner's manual
in the vehicle glove box.
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Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 6008
Remote Switch: Testing and Inspection
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system
capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the
steering wheel.
Remote Radio Switches
3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test
table.
REMOTE RADIO SWITCH TEST Switch position = Resistance Volume Up = 7320 Ohms Volume
Down = 1210 Ohms Seek Up = 4530 Ohms Seek Down = 2050 Ohms Pre-set station advance =
10 Ohms
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right"/Left remote radio switch orientation is with the steering wheel installed, and driver in
drivers seat.
4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check
for continuity between the ground circuit cavity of the switch wire harness connector and a good
ground. There should be continuity If OK,
go to Step 6. If not OK, repair the open circuit as required.
6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check
for continuity between the radio control circuit
cavity of the remote radio switch wire harness connector and a good ground. There should be no
continuity If OK, go to Step 7. If not OK, repair the short circuit as required.
7. Check for continuity between the radio control circuit cavities of the remote radio switch wire
harness connector and the BCM wire harness
connector. There should be continuity If OK, refer to the proper Diagnostic Procedures to test the
BCM and the CCD data bus. If not OK, repair the open circuit as required.
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Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 6009
Remote Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system
capacitor to discharge before further service. 2. From the underside of the steering wheel, remove
the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the airbag
module away from the steering wheel far enough to access the wire harness connectors on the
back of the airbag module. 4. Unplug the airbag module and horn switch wire harness connectors
from the back of the airbag module. 5. Remove the driver side airbag module from the vehicle. 6.
Remove the steering wheel from the steering column. 7. Unplug the wire harness connector from
the remote radio switch(s). 8. Remove three screws securing steering wheel rear cover. 9. Remove
the remote radio switch from the steering wheel by depressing tabs on each side of switch.
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right/left remote radio switch orientation is with the steering wheel installed, and driver in
drivers seat.
INSTALLATION
For installation, reverse the above procedure. The switches can only be installed one way. Be
careful to index them correctly before pressing them into place.
Tighten the airbag module mounting screws to 10.2 Nm (90 in. lbs.).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Diagrams
Trunk/Liftgate Sensor/Switch (For Alarm): Diagrams
Hood Ajar Switch
Liftgate Arm/Disarm Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar
(VTSS Trigger) Switch
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate latch from the vehicle.
3. Disconnect the wire connector from the liftgate ajar switch.
Liftgate Ajar Switch
4. Remove the screw holding the ajar switch to the liftgate latch and remove the switch.
INSTALLATION
For installation, Reverse the above procedure.
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Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar
(VTSS Trigger) Switch > Page 6015
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Key Cylinder Switch
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate trim panel. 3.
Disconnect the liftgate key cylinder switch wire connector from the liftgate harness and clip from the
liftgate inner panel. 4. Remove the liftgate outside handle.
Liftgate Cylinder Lock Switch
5. Disconnect the lock tab holding the switch to the back of lock cylinder and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Component Information > Diagrams > Diagram Information and Instructions > Page 6027
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Component Information > Diagrams > Diagram Information and Instructions > Page 6028
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Component Information > Diagrams > Diagram Information and Instructions > Page 6032
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Trailer Connector: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6043
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Diagrams > Diagram Information and Instructions > Page 6045
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Diagrams > Diagram Information and Instructions > Page 6046
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Diagrams > Diagram Information and Instructions > Page 6047
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Diagrams > Diagram Information and Instructions > Page 6048
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Diagrams > Diagram Information and Instructions > Page 6049
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6050
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Diagrams > Diagram Information and Instructions > Page 6051
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diagrams > Diagram Information and Instructions > Page 6052
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Diagrams > Diagram Information and Instructions > Page 6053
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Diagrams > Diagram Information and Instructions > Page 6054
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Diagrams > Diagram Information and Instructions > Page 6055
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Diagrams > Diagram Information and Instructions > Page 6056
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Diagrams > Diagram Information and Instructions > Page 6057
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Diagrams > Diagram Information and Instructions > Page 6058
Trailer Connector: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Locations
Compass/Mini-Trip Computer
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions
Trip Computer: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 6066
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 6067
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 6068
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Diagram Information and Instructions > Page 6069
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Diagrams >
Diagram Information and Instructions > Page 6070
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Diagram Information and Instructions > Page 6071
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Diagram Information and Instructions > Page 6072
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Diagram Information and Instructions > Page 6073
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Diagram Information and Instructions > Page 6077
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Diagram Information and Instructions > Page 6078
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Diagram Information and Instructions > Page 6080
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Diagram Information and Instructions > Page 6081
Trip Computer: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Compass/Mini-Trip Computer
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Compass/Mini-Trip Computer
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Page 6086
Trip Computer: Description and Operation
COMPASS/MINI-TRIP COMPUTER
The Compass/Mini-Trip Computer is located in the overhead console. The CMTC consists of a
electronic control module with a vacuum fluorescent display (VFD) and function switches. It
displays to the driver the direction the vehicle is traveling and the current outside temperature, as
well as the following traveler navigational information: Average Fuel Economy (AVG ECO)
- Distance To Empty (DTE)
- Instantaneous Fuel Economy (ECO)
- Elapsed Time (ET)
- Trip Odometer (ODO).
Pushing the STEP button when the ignition is ON will cause the CMTC to change mode of
operation.
The information needed for the traveler functions is received over the CCD bus from the Body
Control Module.
If the Compass/Mini-Trip Computer has been replaced, it may be necessary to reset the calibration.
SYSTEM OPERATION
Compass/Mini-Trip Computer Self Diagnostic Test
The Compass/Mini-Trip Computer (CMTC) is capable of performing a diagnostic self check on
many of its internal functions. CMTC diagnostics may be performed using a DRB lll scan tool and
the proper Body Diagnostic Procedures or by the following procedure.
1. With the ignition switch in the OFF position, press both the US/M and STEP button. 2. Turn
ignition switch to the ON position.
The CMTC will perform internal checks while lighting all segments of the vacuum florescent
display. Upon completion of the internal check, the CMTC will display: PASS
- FAIL
- CCD
If any segment of the CMTC fails to light, replace the module.
If FAIL is displayed, replace the module.
If CCD is displayed, check the CCD and Body Control Module (BCM) for proper operation, refer to
the appropriate diagnostic test procedures. If the CCD and the BCM are OK, replace the CMTC
module.
For additional diagnostic information on the CMTC and for identifying CMTC problems, refer to the
proper Body Diagnostic Procedures.
Compass Mini-Trip Computer (CMTC)
Compass Mini-Trip Computer (CMTC) Switches and Display
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Page 6087
The CMTC module in the overhead console has three buttons used to select various functions. The
CMTC selector buttons will not operate until the ignition is in the RUN position.
When the ignition switch is first turned to the RUN position the CMTC display: Blanks momentarily
- All segments of the VFD will light for one second
- Blanks momentarily
- Returns to the last mode setting selected before the ignition was last switched OFF.
Thermometer
Engine temperature can increase the displayed temperature. The CMTC is designed to dampen
temperature readings when the vehicle is moving at a rate slower than 18 miles per hour.
The outside temperature is measured from a sensor mounted in the front of the vehicle. If the
temperature is more than 55 °C (131 °F) or the temperature sending line is shorted to ground, the
temperature display should read SC. If the temperature is less than -40 °C (-40 °F), or the sending
line is an open circuit, the display should read OC.
The CMTC will not allow the temperature reading to increase when the vehicle is not moving.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Testing and
Inspection > Testing
Trip Computer: Testing and Inspection Testing
The Compass Mini Trip Computer (CMTC) is capable of performing a diagnostic self check on
many of its internal functions. CMTC diagnostics may be performed using a scan tool and the
proper Body Control Module Testing and Inspection Procedures or by using the following
procedure.
1. With the ignition switch in the OFF position, press both the US/M and STEP buttons. 2. Turn
ignition switch to the ON position. The CMTC will perform internal checks while lighting all
segments of the vacuum florescent display.
Upon completion of the internal check the CMTC will display. PASS
- FAIL
- CCD
If any segment of the CMTC fails to light replace the module.
If FAIL is displayed replace the module.
If CCD is displayed check the CCD (Information Bus) and Body Control Module (BCM) for proper
operation. If the CCD bus and the BCM are OK, replace the CMTC module.
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
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Trip Computer: Testing and Inspection Traveler Messages
Traveler data is obtained from the Body Control Module (BCM) on the CCD bus wires. The CMTC
will not display information for any of the screens for which it did not receive the bus messages.
The label corresponding to the missing information will be lit. If no traveler data is displayed, check
the CCD bus communications and the BCM. If the brightness level is improper check the CCD bus.
One general method for checking the CCD bus communications between CMTC and the BCM is
refer to the following procedure.
1. STEP the CMTC to the Elapsed Time (ET). 2. Press and release the reset button to reset the
module. 3. If the elapsed time clock does not reset, or fails to update, check the CCD bus wires
and the BCM. The DRB lll is recommended for checking the
CCD bus and the BCM.
4. Perform the CMTC self diagnosis before replacing the CMTC.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and
Repair > Compass/Mini-Trip Computer (CMTC) Lamp Bulbs
Trip Computer: Service and Repair Compass/Mini-Trip Computer (CMTC) Lamp Bulbs
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. Refer to Body
and Frame/Interior Trim/Overhead Console Replacement.
CMTC Lamp Bulbs
3. Rotate bulb socket counterclockwise one quarter turn.
INSTALLATION
For installation, reverse the above procedures.
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Trip Computer: Service and Repair Compass/Mini-Trip Computer (CMTC) Module
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. Refer to Body
and Frame/Interior Trim/Overhead Console Replacement.
Compass Mini-Trip Computer
3. Remove the six screws holding CMTC module to overhead console. 4. Remove CMTC module
from console.
INSTALLATION
For installation, reverse the above procedures.
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Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Technical Service Bulletins > Electrical - Wiring Schematics Revisions
Body Control Module: Technical Service Bulletins Electrical - Wiring Schematics Revisions
NUMBER: 26-12-99G
GROUP: Miscellaneous
DATE: December, 1999
THE REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revisions to the wiring schematics
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8W-44-5
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8W-44-7
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8W-45-7
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Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6103
8W-50-2
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Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6104
8W-50-5
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Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6105
8W-50-7
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Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6106
8W-80-15
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Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6107
8W-90-3
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Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6108
8W-90-11
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Body Control Module: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out
Revisions
NUMBER: 26-04-99
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
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Technical Service Bulletins > Electrical - Wiring Schematics Revisions > Page 6110
8N-4
Revision to the Body Control Module connector pin-out
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8W-80-13
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Body Control Module: Technical Service Bulletins Body Control Module - Erroneous DTC Set
NO: 18-25-98
GROUP: Vehicle Performance
DATE: Aug. 14, 1998
SUBJECT: Erroneous Body Control Module Diagnostic Trouble Code
MODELS:
1999 (NS) Town & Country/Caravan/Voyager 1999 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE TRANSAXLE.
DISCUSSION:
During service diagnostic procedures, the Body Control Module (BCM) may indicate an erroneous
"EATX PRNDL NOT RECEIVED" Diagnostic Trouble Code (DTC). If this DTC exists, turn the
ignition to the ON position and determine if each PRNDL indicator in the instrument cluster
becomes boxed (all boxed at the same time) after ten seconds. If all PRNDL indicators do NOT
become boxed at the same time, the DTC is erroneous and the DTC should be cleared, it is not
necessary to replace the BCM.
NOTE:
CHRYSLER HAS NOT RECEIVED ANY REPORTS OF THIS DTC BEING SET BY AN ACTUAL
FAILURE IN THE PRNDL SYSTEM.
POLICY: Information Only
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Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics
NO: 08-40-98
GROUP: Electrical
DATE: Sept. 25, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED
DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL
VEHICLES.
MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager
DISCUSSION:
During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp
Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head
lamps.
If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at
erasing this erroneous DTC will be unsuccessful.
If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan,
Voyager and Town & Country Body Diagnostic Procedures Manual.**
POLICY: Information Only
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Locations > Component Locations
Body Control Module: Component Locations
Body Control Module
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Junction Block, Body Control Module
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Body Control Module: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Body Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Body Control Module: Connector Views
Body Control Module C1 (A)
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Body Control Module C2 (B)
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Junction Block
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Body Control Module Interconnect
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Body Control Module: Electrical Diagrams
BCM Block Diagram
Wiring Diagrams
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Body Control Module -- Sheet 8w-45-2
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Body Control Module -- Sheet 8w-45-3
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Body Control Module -- Sheet 8w-45-4
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Body Control Module -- Sheet 8w-45-5
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Body Control Module -- Sheet 8w-45-6
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Body Control Module -- Sheet 8w-45-7
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Body Control Module -- Sheet 8w-45-8
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Body Control Module -- Sheet 8w-45-9
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
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Body Control Module: Service Precautions
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
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Description and Operation > Part 1 of 3
Body Control Module: Description and Operation Part 1 of 3
INTRODUCTION
Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION
AIRBAG SYSTEM The airbag system is designed to provide increased driver and passenger
protection if the vehicle is involved in a front end collision. The system is most effective when used
in conjunction with the seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. This information will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
Functional Operation Whenever the ignition key is turned to the "run" or "start" position, the airbag
control module (ACM) performs a lamp check by turning the AIRBAG warning lamp ON. The lamp
stays lit for 6 to 8 seconds, then goes off. If the lamp remains OFF, it means that the ACM has
checked the system and found it to be free of discernible malfunctions. The airbag system is
monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures in this book to find the cause of any customer complaint regarding the
AIRBAG warning lamp, such as: warning lamp does not come on at all
- warning lamp stays on
BODY CONTROL MODULE The body control module (BCM) supplies vehicle occupants with
visual and audible information and controls various vehicle functions. To provide and receive
information, the module is interfaced to the vehicle's serial bus communications network (the
Chrysler Collision Detection bus, or CCD bus). This network consists of the powertrain control
module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster
(MIC), the airbag control module (ACM), the compass/mini- trip module and the controller antilock
brake (CAB) module. The BCM is operational when battery power is supplied to the module.
Ignition switch power is needed for ignition switch functions.
The body control module provides the following features: automatic door locks
- battery protection
- CCD radio
- chimes
- compass/mini-trip support
- courtesy lamps
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
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- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid
wearing down the battery if the customer leaves the parklamps or headlamps on for extended
periods of time with the ignition OFF. If the parklamp or headlamp switch remains in the active
position for more than 3 minutes, while the ignition is OFF, the parklamps and or headlamps will be
turned off and the input causing the lamps to be ON will be ignored. Once the 3 minute time-out has
elapsed the BCM will enter sleep mode. Any change in any inputs monitored by the BCM that
brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock), door ajar,
ignition, RKE actuation, etc.).
Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory
power ON) will inhibit the battery protection routine from turning OFF the exterior lamps as
described above.
Battery Protect: "Reading & Glove Box Lamps" This feature provides a battery protection scheme to
avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity
mirrors ON. The BCM provides a ground circuit for these interior lamps. This ground path is
connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters
sleep mode. Once the 15 minutes time-out has expired, any monitored input that brings the BCM
out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central
Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and
vanity mirrors to normal operation (normal operation defined as: "ON" is reading lamp and visor
vanity mirrors ON, or glove box open; "OFF" if reading lamp and visor vanity mirrors OFF, and
glove box closed).
Leaving the keys in the ignition switch, while the ignition is OFF, will not inhibit the battery
protection from turning off these interior lamps as described above. Leaving the ignition switch in
an active position (steering column unlocked, ignition ON or accessory power on) will inhibit the
battery protection routine from turning off these interior lamps as described above.
Shipping Mode By definition, shipping mode is when the IOD fuse is removed from the vehicle. The
BCM receives its primary power feed from the battery via the IOD fuse. The BCM also receives a
back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry,
courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is
reconnected or the ignition switch is turned to the run/start position.
Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which
are controlled by the body controller module (BCM). When the parklamp switch is closed to ground
the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same
parklamp power feed is also wired back into the BCM to provide the power feed for the PWM
circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and
high beam headlamp relays. The position of the hi-beam select switch will determine the mode of
operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and
low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of
operation at a time.
Auto Headlamps On vehicles equipped with the auto headlamp feature, the BCM will control the
exterior lamp operation by monitoring the mode selection switch located in the headlamp control
panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the
Electro-Chromic Rear View mirror. The mirror will determine the appropriate ambient light levels for
turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to
darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see
Headlamp Delay Feature description).
Headlamp Time Delay The headlamp Delay feature keeps the Headlamps on for 60 seconds giving
the driver and passengers security lighting when exiting the vehicle. This feature is only available
on vehicles equipped with RKE. The Headlamp Delay feature is activated by sequentially turning
off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be
turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45
second window is new for the NS body Once the headlamp delay has been activated the
headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the
ignition switch changes states.
CHIME SYSTEM The chime system provides the driver with two types of chimes: warning and
announcement. Warning chimes are provided for dome lamps on, engine temperature lamp,
exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above
15 mph). The warning chime will sound continuously until the condition is removed or the battery
protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for
approximately six seconds or until the seat belt is fastened, The announcement chime will sound
one time whenever the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar
lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the
vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the
instrument cluster warning lamp diagnostics.
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Body Control Module: Description and Operation Part 2 of 3
COMPASS/MINI-TRIP COMPUTER
The compass/mini-trip computer is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE),
instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information
needed for the traveler functions is received over the CCD bus from the body control module.
If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration.
Setting The Compass The compass/mini-trip module is self-calibrated and requires no adjustment.
The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL
will turn off after the vehicle has gone in three complete circles without stopping, in an area free of
magnetic disturbance.
If the module displays the temperature while the compass is blank or shows a false reading, the
vehicle must be demagnetized. See the service procedure.
If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module
must be replaced.
Compass Magnetic Variance Zones
Setting The Variance Variance is the difference between magnetic north and geographic north. To
determine the variance for the area you are in, refer to the following zone map provided. The
number shown for your area is the variance number for your area. 1. Set the compass/mini-trip
console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5
seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the
variance to 8 and enter the fast calibration mode.
3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP
button to set the zone number. 5. Press the US/M button and resume normal operation,
NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO
THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS.
MECHANICAL INSTRUMENT CLUSTER (MIC) The body control module sends the angular
position of the gauges, the status of all CCD indicator lamps, the status and dimming of the
mechanical instrument cluster (MIC) over the CCD bus when the ignition is in the "off,, (unlock),
"run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the
ignition is in the "OFF" (unlock), "run", or "start" positions; all other MIC features work only when
ignition is in the "run position. On transition of the ignition from the "OF"' to the "run" position, a bulb
check is performed. This consists of activating all CCD controlled indicator lamps and all VF display
segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is
moved from the PARK position, or if the engine exceeds 450 rpm.
POWER DOOR LOCK SYSTEM When the BCM receives an input for a lock request (door lock
switch, RKE, or door key cylinder switch (only with VTSS)), it will ground the lock-relay coil for a
specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1
second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door
lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The
unlock signal operates in the same fashion as the lock signal. The door Lock switches provide a
variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the
BCM will respond to that command.
Other power Door Lock features: Sliding Door Memory Lock- When the BCM receives an input for
a lock request and a sliding door is open, the BCM will turn on the lock relay
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as described above, and will turn it on again when all sliding doors are closed.NOTE: If the BCM
receives an unlock input before a sliding door is closed this action will cancel the memory lock.
Door Lock Inhibit- When the key is in the ignition and in the off position, and any door except the
rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional.
This protects against locking the vehicle with the keys still in the ignition.
Automatic Door Locks- This feature can be enabled or disabled by using either the DRBIII or
customer programming method. When enabled, all the doors will lock when the vehicle reaches a
speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15
MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH.
RKE (Remote Keyless Entry) Interface- The body control module interfaces with the RKE receiver
via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the
BCM depending on which button on the transmitter was pressed. The BCM controls the door
lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The
RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the
PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the
RKE.
The RKE module can be programmed via the DRBIII or customer programming method. The BCM
will only allow programming mode to be entered when the ignition is in the ON position, the PRNDL
is in park position, and the VTSS (if equipped) is in the disarmed mode.
Programming an RKE Transmitter
Customer Programming Method
NOTE: A VALID, PREVIOUSLY PROGRAMMED TRANSMITTER MUST BE USED.
1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition on, place the transmission
in park, and make sure the vehicle theft security system (if equipped) is in disarm mode. 3.
Using the previously programmed transmitter, press and hold the unlock button for 4 to 8 seconds.
While still holding the unlock button, press the panic button, then release both buttons. The BCM
will acknowledge that it has grounded the RKE module program enable wire by sounding a single
chime tone.
4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has
accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle
(up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode
sooner, turn the ignition off.
DRB Programming 1. Ensure batteries are approximately 3.2 volts each. 2. Turn the ignition ON,
place the transmission in park, and make sure the vehicle theft security system (if equipped) is in
disarm mode. 3. Select Program RKE" under "Miscellaneous". If the message "BCM is in
Programming Mode" does not appear, exit and select "Program
RKE" again.
4. Press any button on the transmitter. A single chime tone will acknowledge the RKE module has
accepted the transmission. 5. Repeat step 4 for all transmitters that will be used with this vehicle
(up to 4 total). 6. Programming mode will last for 30 seconds. To get out of programming mode
sooner, press "Back Page".
RADIO SYSTEM There are three radio systems available this year that will be on the CCD bus.
They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the
radio remote controls in the steering wheel. They can control volume up/ down, seek up, seek
down and preset station selections. These systems also communicate with the body control
module and will set a specific code if there is a problem with the remote controls.
The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of
the 4 main quarter speakers have a built in amplifier. The I/P and pillar speakers receive their
signals from the quarter speakers. Depending on the manufacture some systems will have a
Front/Rear channel system and others will have a Left/Right channel system. If one of the main
quarter speaker audio circuits experiences a short, the other speakers on that channel will also
shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible
with the DRB, indicating which channel is effected.
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Body Control Module: Description and Operation Part 3 of 3
VEHICLE COMMUNICATION The body system consists of a combination of modules that
communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD
bus, information about the operation of vehicle components and circuits is relayed to the
appropriate module(s). Each module receives the same information about a component or circuit
as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and
the size of the wiring harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system called "bus +" (bus plus)
and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts.
In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded
messages, there is a "voltage divider network". This network consists of some modules with bias
and some with termination. Bias is the part of the voltage divider network that places both bus +
and bus - at 2.5 volts.Termination in the circuitry is required to complete the voltage divider network
and also provides some electromagnetic protection for the bus.
NOTE: COMMUNICATION OVER THE BUS IS ESSENTIAL TO THE PROPER OPERATION OF
THE VEHICLE'S ON-BOARD DIAGNOSTIC SYSTEMS AND THE DRB. PROBLEMS WITH THE
OPERATION OF THE BUS OR DRB MUST BE CORRECTED BEFORE PROCEEDING WITH
DIAGNOSTIC TESTING. IF THERE IS A PROBLEM, REFER TO THE VEHICLE
COMMUNICATIONS.
Any of the following bus failure messages may be displayed. Short to Battery- Either or both of the
bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are
shorted to a 5-volt potential. Short to Ground- Either or both of the bus wires are shorted to ground
or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are
shorted together. No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly
above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules
that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus
Messages Correctly - The DRB cannot communicate over the bus and does not know why.
VEHICLE THEFT SECURITY SYSTEM This passive system is designed to protect against theft.
The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle
hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the
horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an
engine "no run" feature.
Passive arming occurs upon normal vehicle exit by turning the ignition OFF, opening the driver's
door, locking the doors with the power lock, and closing the driver's door or locking the doors with
RKE. Manual arming occurs by using the key to lock the doors after closing them. The indicator
lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no
monitored systems are activated during this period, the system Will arm. If the hood ajar switch is
seen as closed circuit by the system, the indicator lamp Will remain steadily lit during the arming
process, although the system will still arm.
When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for
about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate
is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override -
The system will not arm if the doors are locked using the manual lock control (by hand) or if the
locks are actuated by an inside occupant after the door is closed.
When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus
to the powertrain control module that it is not OK to start the engine. The powertrain control module
then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting
down the engine (start and stall condition). The engine will not start until the system is disarmed.
To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but
keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE:
After the doors are closed, locking the doors with RKE will also arm the system.
NOTE: IF THE VTSS INDICATOR LAMP FLASHED, THE SYSTEM IS OPERATIONAL AND
VERIFIED. IF NOT, THERE MAY BE A PROBLEM WITH THE SYSTEM.
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System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is
closed. 1. Rotating the key in liftgate cylinder to unlock/disarm position.
Arming/Disarming- Active arming occurs when the remote keyless entry transmitter is used to lock
the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming
sequence is completed only after all door are closed.
Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with
the key). This disarming also will halt the alarm once it has been activated.
Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle
doors. This disarming also will halt the alarm once it has been activated.
System Self-Test - NOTE: System self-test can be entered only with the DRB.
NOTE: A POWERTRAIN CONTROL MODULE FROM A VEHICLE EQUIPPED WITH A VEHICLE
THEFT SECURITY SYSTEM CANNOT BE USED IN A VEHICLE THAT IS NOT EQUIPPED WITH
A VEHICLE THEFT SECURITY SYSTEM.
If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication
with the powertrain control module possibly has been lost.
WIPER SYSTEM
Front The front wiper system provide the driver with normal wipe (low and high speeds),
intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function
via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the
on position and the ignition is turned OFF the wiper will continue to run until it reaches its park
position.
Other front wiper system features: Speed Sensitive Intermittent Wipe Mode- There are 6 individual
delay times with minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle
speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36
seconds.
Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more
than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided.
Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then
releases it, the wiper will continue to run for 2 additional wipe cycles.
Rear The rear wiper system provides the driver with continuous, intermittent, and wiper after wash
functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the
HVAC control.
DRB III (R) ERROR MESSAGES
Under normal operation, the DRB will display one of only two error messages: - User-Requested
WARM Boot or User- Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the MDS
Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error
message display:
ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD
Boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRB III (R) Does Not Power UP (Blank Screen) If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data
link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A.
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DRB Scan Tool
Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to
compensate for this condition
WARNINGS
Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is
"OFF". Failure to do so could damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals, Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair
verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or
symptom condition.
CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE
REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN
WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE
IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB.
REQUIRED TOOLS AND EQUIPMENT
DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires
ohmmeter voltmeter oil pressure gauge (0-300 psi) test light
GLOSSARY OF ACRONYMS
ACM Airbag Control Module
AECM Airbag Electronic Control Module (type of ACM)
ASDM Airbag System Diagnostic Module (type of ACM)
BCM body control module
CAB controller antilock brake
CCD Chrysler Collision Detection (vehicle communications bus)
CMTC
Compass/Mini-Trip Computer (module)
DLC data link connector (previously called "engine diagnostic connector")
DR driver
HVAC heater, ventilation, air condition
MET metric
MIC mechanical instrument cluster
MUX multiplexed
ODO odometer
PASS passenger
PCM powertrain control module
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PDC powertrain distribution center
PTC positive temperature coefficient
RKE remote keyless entry
TCM transmission control module
VF vacuum fluorescent display
VTSS
vehicle theft security system
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures
Body Control Module: Symptom Related Diagnostic Procedures
AM/FM Switch Inoperative
SYMPTOM
* AM/FM SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Balance Joystick Inoperative
SYMPTOM
* BALANCE JOYSTICK INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Cassette Error
SYMPTOM
CASSETTE ERROR
POSSIBLE CAUSES
- Cassette Error / Replace radio
CD Eject Switch Inoperative
SYMPTOM
* CD EJECT SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
CD Error
SYMPTOM
CD ERROR
POSSIBLE CAUSES
- Defective radio
Equalizer Inoperative
SYMPTOM
* EQUALIZER INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
External CD Changer (If Equipped)
SYMPTOM
* EXTERNAL CD CHANGER (IF EQUIPPED)
POSSIBLE CAUSES
- Radio/CD cable loose/disconnected
- DIN cable data bus (CAV 1) open
- DIN cable data bus (CAV 3) open
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- DIN cable terminals shorted
- DIN signal wires (CAVS 2, 4, and 5) open
- DIN fused B(+) circuit open
- DIN fused ignition switch output circuit open
- DIN ground circuit open
- DIN metal connectors open
- Radio defective
- Radio input control defective
FF/RW Switch Inoperative
SYMPTOM
* FF/RW SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Hour/Minute Switch Inoperative
SYMPTOM
* HOUR/MINUTE SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
No Sound From All Speakers
SYMPTOM
* NO SOUND FROM ALL SPEAKERS
POSSIBLE CAUSES
- Radio 12V output circuit defective, open
- Radio ground circuit defective, open
- Power relay output circuit defective, open
- Radio 12V output circuit shorted to ground
- Radio choke defective
- Speaker power relay defective, open
- Speaker power relay defective, open
- Junction block defective, open circuit
- Defective radio
- Radio choke output circuit defective, open
- Radio output circuits defective
No Sound From One Speaker
SYMPTOM
* NO SOUND FROM ONE SPEAKER
POSSIBLE CAUSES
- Door or quarter speaker (+) circuit defective, open
- Door or quarter speaker (-) circuit defective, open
- Door or quarter speaker (+) circuit open
- Door or quarter speaker (-) circuit open
- Instrument panel or pillar speaker (+) circuit open
- Instrument panel or pillar speaker (-) circuit open
- Door or quarter speaker defective
- Speaker defective, no response
Pause/Play Switch Inoperative
SYMPTOM
* PAUSE/PLAY SWITCH INOPERATIVE
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6163
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Poor Sound Quality All Speakers
SYMPTOM
* POOR SOUND QUALITY ALL SPEAKERS
POSSIBLE CAUSES
- Antenna connector defective
- Antenna connections defective
- Hood ground defective
- Ground circuit defective, open
- Radio connectors not properly connected
- Ignition / alternator system noise
- Radio defective
Poor Sound Quality From One Speaker
SYMPTOM
* POOR SOUND QUALITY FROM ONE SPEAKER
POSSIBLE CAUSES
- Ground circuit open
- Instrument panel - pillar speaker defective
- Radio choke output circuit open
- Speaker (+) and (-) circuits shorted together
- Inoperative speaker defective
PWR Switch Inoperative
SYMPTOM
* PWR SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Radio Error
SYMPTOM
RADIO ERROR
POSSIBLE CAUSES
- Defective radio
Remote Controls Inoperative
SYMPTOM
* REMOTE CONTROLS INOPERATIVE
POSSIBLE CAUSES
- No response, CCD bus failure
- Radio control harness defective, open
- Radio control MUX circuit shorted
- Remote control switch defective
- MUX control clockspring defective
- Radio control ground circuit to BCM open
- Radio control MUX circuit open
- Radio MUX control circuit defective
- Body Control Module defective
Scan Switch Inoperative
SYMPTOM
* SCAN SWITCH INOPERATIVE
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6164
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Seek Switch Inoperative
SYMPTOM
* SEEK SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Set Switch Inoperative
SYMPTOM
* SET SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Shorted Front Channel
SYMPTOM
SHORTED FRONT CHANNEL
POSSIBLE CAUSES
- Left door speaker shorted
- Left front instrument panel speaker shorted
- Right door speaker shorted
- Right front instrument panel speaker shorted
- Right front (-) circuit shorted to ground
- Right front (+) and (-) circuits shorted together
- Right front (+) circuit shorted to ground
- Left front (+) and (-) circuits shorted together
- Left front (+) circuit shorted to ground
- Left front (-) circuit shorted to ground
- Radio output circuits defective
Shorted Left Channel
SYMPTOM
SHORTED LEFT CHANNEL
POSSIBLE CAUSES
- Left door speaker defective, shorted
- Left front instrument panel speaker defective, shorted
- Left quarter speaker shorted
- Left rear (+) and (-) circuits shorted together
- Left rear (+) circuit shorted to ground
- Left rear (-) circuit shorted to ground
- Left rear speaker shorted
- Left front (+) and (-) circuits shorted together
- Left front (+) circuit shorted to ground
- Left front (-) circuit shorted to ground
- Radio output circuits defective
Shorted Rear Channel
SYMPTOM
SHORTED REAR CHANNEL
POSSIBLE CAUSES
- Right rear quarter speaker shorted
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6165
- Left rear (+) and (-) circuits shorted together
- Left rear (+) circuit shorted to ground
- Left rear (-) circuit shorted to ground
- Left rear quarter speaker shorted
- Left rear speaker shorted
- Right rear (+) and (-) circuits shorted together
- Right rear (+) circuit shorted to ground
- Right rear (-) circuit shorted to ground
- Right rear pillar speaker shorted
- Radio output circuits defective
Shorted Right Channel
SYMPTOM
SHORTED RIGHT CHANNEL
POSSIBLE CAUSES
- Right channel speaker shorted
- Right instrument panel speaker defective, shorted
- Right front (+) circuit shorted to ground
- Right front (+) and (-) circuits shorted together
- Right front (-) circuit shorted to ground
- Right pillar speaker shorted
- Right quarter speaker shorted
- Right rear (+) and (-) circuits shorted together
- Right rear (+) circuit shorted to ground
- Right rear (-) circuit shorted to ground
- Radio output circuits defective
Tape Eject Switch Inoperative
SYMPTOM
* TAPE EJECT SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Tune Switch Inoperative
SYMPTOM
* TUNE SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
Volume/Time Switch Inoperative
SYMPTOM
* VOL/TIME SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test * 1-5 PRESETS INOPERATIVE.
POSSIBLE CAUSES
- Radio function controls inoperative
1-5 Presets Inoperative
SYMPTOM
* 1-5 PRESETS INOPERATIVE
POSSIBLE CAUSES
- Radio function controls inoperative
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6166
Chime Inoperative at All Times
SYMPTOM
* CHIME INOPERATIVE AT ALL TIMES
POSSIBLE CAUSES
- BCM fails chime test
Chime Inoperative With Driver Seat Belt Unfastened
SYMPTOM
* CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED
POSSIBLE CAUSES
- Ground circuit to left seat belt switch connector open
- Left seat belt switch open
- BCM not responding to belt switch
- Body Control Module seat belt switch sense open
- Seat belt switch sense circuit open
Chime Inoperative With Engine Temperature Critical
SYMPTOM
* CHIME INOPERATIVE WITH ENGINE TEMPERATURE CRITICAL
POSSIBLE CAUSES
- BCM - No response to oil pressure
- BCM fails chime test
Chime Inoperative With Exterior Lamps On
SYMPTOM
* CHIME INOPERATIVE WITH EXTERIOR LAMPS ON
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition Switch - key in switch shorted
- BCM - no chime response - head/park lamps ON
- BCM - key in sense shorted default
- BCM - no response to park lamp switch
- Chime inoperative with exterior lamps ON
Chime Inoperative With Key In Ignition & Driver Door Open
SYMPTOM
* CHIME INOPERATIVE WITH KEY IN IGNITION & DRIVER DOOR OPEN
POSSIBLE CAUSES
- Ignition switch ground circuit open
- Key in ignition switch sense circuit open
- Ignition switch - key in switch open
- BCM - no chime to key in ignition
- BCM not responding to key in switch
Chime Inoperative With L or R Turn Signal On For 1 Mile
SYMPTOM
* CHIME INOPERATIVE WITH LEFT OR RIGHT TURN SIGNAL ON FOR 1 MILE
POSSIBLE CAUSES
- Junction block - Left turn signal open
- Junction block - Right turn signal open
- BCM - no response to turn signal
- BCM fails speed test
- Chime - speedometer problem
- Chime inoperative - turn signal on for 1 mile
Chime Inoperative With Low Oil Pressure
SYMPTOM
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6167
* CHIME INOPERATIVE WITH LOW OIL PRESSURE
POSSIBLE CAUSES
- BCM - No response to oil pressure
- BCM fails chime test
Chime Inoperative With the Dome Lamps On
SYMPTOM
* CHIME INOPERATIVE WITH THE DOME LAMPS ON
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition switch - key in switch shorted
- BCM failed - door open & key out default
- BCM - key in switch sense shorted default
Chime Sounds With Driver Door Open & Key Out
SYMPTOM
* CHIME SOUNDS WITH DRIVER DOOR OPEN & KEY OUT
POSSIBLE CAUSES
- Key in ignition switch sense circuit shorted
- Ignition switch - key in switch shorted
- BCM - key in switch sense shorted default
- BCM not responding to key out
Chime Sounds With Driver Seat Belt Fastened
SYMPTOM
* CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED
POSSIBLE CAUSES
- Seat belt switch sense circuit shorted to ground
- Left seat belt switch shorted
- BCM - no response to seat belt fastened
- BCM seat belt switch input shorted to ground
Auto Headlamps Will Not Turn Off
SYMPTOM
* AUTO HEADLAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- No response (PCM) - CCD bus failure
- Auto headlamp signal circuit open
- Auto headlamp signal circuit shorted to ground
- Electrochromic mirror defective - sensor stuck ON (default)
- BCM defective - auto headlamp sensor stuck ON
Auto Headlamps Will Not Turn On
SYMPTOM
* AUTO HEADLAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- NO response (BCM) - CCD bus failure
- NO response (PCM) - CCD bus failure
- Auto headlamp signal circuit open
- Electrochromic mirror defective (default)
- BCM defective - auto headlamp sensor
Fog Lamps Will Not Turn Off
SYMPTOM
* FOG LAMPS WILL NOT TURN OFF
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6168
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Fog lamp switched ground circuit shorted to ground
- Headlamp switch defective - foglamp switched ground
Fog Lamps Will Not Turn On
SYMPTOM
* FOG LAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Fog lamp bulbs open
- Fog lamp relay control circuit open
- Fog lamp relay output circuit open
- Fog lamp relay defective, open
- Multifunction dimmer switch defective (open) default
- Fog lamp switched ground circuit open
- BCM defective - Headlamp relay control
- Multifunction switch defective (fog lamp relay control) default
- Headlamp relay control circuit (foglamps) open
Headlamps Will Not Turn Off
SYMPTOM
* HEADLAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch sense circuit shorted to ground
- Headlamp relay control circuit shorted to ground
- Low beam relay control circuit shorted to ground
- Low beam relay control circuit (QUAD) shorted to ground
- Low beam headlamp relay (QUAD) defective, shorted
- Low beam headlamp relay defective (shorted) by default
- PDC defective (low beam headlamp relay connector shorted)
- Headlamp switch defective - switch sense
- BCM defective (headlamp switch sense function) by default
- BCM defective (low beam relay control shorted) by default
Headlamps Will Not Turn On
SYMPTOM
* HEADLAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch ground circuit open
- Both low beam fuses open
- Fused low beam output circuit open (both lamps inoperative)
- Fused low beam output circuit open (one lamp inoperative)
- Headlamp defective (by default)
- Headlamp fuse open
- Headlamp switch sense circuit open
- Headlamps defective (by default)
- Multifunction switch defective (default)
- Headlamp relay control circuit open
- Low beam relay control circuit (Chrysler) open
- Low beam relay control circuit open
- Low beam headlamp relay defective (by default)
- Low beam relay defective - relay control function
- PDC defective - B(+) circuit at low beam fuse terminal
- Power Distribution Center defective (low beam relay CAV A)
- Power Distribution Center defective (low beam relay CAV B)
- Headlamp switch defective (by default)
- BCM defective - headlamp switch sense function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6169
- BCM defective - headlamp switch sense stuck open
- BCM defective - low beam relay control open
Park Lamps Will Not Turn Off
SYMPTOM
* PARK LAMPS WILL NOT TURN OFF
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Park lamp relay control circuit shorted to ground
- Park lamp relay output circuit shorted to voltage
- Park lamp switch sense circuit shorted to ground
- Park lamp relay defective - control shorted (by default)
- Headlamp switch defective - shorted
- BCM defective - park lamp switch sense closed (by default)
Park Lamps Will Not Turn On
SYMPTOM
* PARK LAMPS WILL NOT TURN ON
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Headlamp switch ground circuit open
- Fused park lamp output circuit open
- Park lamp bulb defective (by default)
- Park lamp fuse in PDC open
- Both park lamp fuses open
- Park lamp fuse open
- Park lamp relay control circuit open
- Park lamp relay output circuit open
- Park lamp switch sense circuit open
- Park lamp relay defective (control function)
- PDC defective - other B(+) cavity
- PDC defective - park lamp relay connector, fused B(+)
- Headlamp switch defective - park lamps (by default)
- BCM defective - park lamp switch sense stuck open
- BCM defective - park lamp switch sense function
- BCM defective - parklamp control function (by default)
ABS Warning Lamp
SYMPTOM
* ABS WARNING LAMP
POSSIBLE CAUSES
- BCM connector observable defect
- CAB connector observable defect
- Fused ignition switch output circuit open
- ABS warning lamp defective
- ABS warning lamp driver circuit open
- ABS warning lamp driver circuit shorted to ground
- ABS warning lamp flashing
- BCM defective
- CAB defective
Airbag Warning Lamp
SYMPTOM
* AIRBAG WARNING LAMP
POSSIBLE CAUSES
- Airbag warning lamp failure
All Warning Lamps Out
SYMPTOM
* ALL WARNING LAMPS OUT
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6170
POSSIBLE CAUSES
- Fused B(+) circuit open
- Fused ignition switch output circuit open
- Ground circuit open
- Information Center defective
Engine Temperature Warning Lamp
SYMPTOM
* ENGINE TEMPERATURE WARNING LAMP
POSSIBLE CAUSES
- Engine temperature lamp staying on
- Temperature lamp not working
- Engine temperature lamp/bulb defective
- Fused ignition switch output circuit open
- Defective BCM
- Engine temperature warning lamp driver circuit open
- Temperature warning lamp driver circuit shorted to ground
- Information Center defective
- Body Control Module defect
- Defective Information Center
High Beam Indicator Lamp
SYMPTOM
* HIGH BEAM INDICATOR LAMP
POSSIBLE CAUSES
- Headlamps inoperative
- Fused right highbeam output circuit open
- Ground circuit open
- High beam indicator bulb defective
- Defective Information Center
Low Oil Pressure Warning Lamp
SYMPTOM
* LOW OIL PRESSURE WARNING LAMP
POSSIBLE CAUSES
- Oil pressure low
- Oil warning lamp/bulb defective
- Oil level low
- Defective oil pressure switch
- Oil pressure switch sense circuit shorted to ground
- Oil pressure switch sense circuit open
- Oil pressure switch defective
- BCM defective
- Defective Information Center
Red Brake Warning Lamp
SYMPTOM
* RED BRAKE WARNING LAMP
POSSIBLE CAUSES
- Park brake pedal problem
- Vehicle equipped antilock brakes
- Brake fluid level low
- Red brake warn lamp/bulb defective
- Ground circuit open
- Brake fluid level switch defective
- Defective ignition switch
- Defective park brake switch
- Red brake warning lamp circuit open
- Red brake warning lamp circuit shorted to ground
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6171
- Information Center faulty
- Ignition switch defective
- Red brake warning lamp driver circuit open
- Red brake warning lamp driver circuit faulty
Service Engine Soon Lamp
SYMPTOM
* SERVICE ENGINE SOON LAMP
POSSIBLE CAUSES
- DTC's are present
- Bulb & socket defective
- Service Engine Soon indicator lamp driver circuit open
- Service Engine Soon indicator lamp circuit shorted to ground
- Defective Information Center circuit board
- Powertrain Control Module defective
Turn Signal Indicator Lamp
SYMPTOM
* TURN SIGNAL INDICATOR LAMP
POSSIBLE CAUSES
- Turn signal lamps inoperative
- Ground circuit open
- Left turn signal circuit open
- Right turn signal circuit open
- Turn signal bulbs defective
- Junction Block defective
- BCM defective
- Information Center defective
Vehicle Theft Alarm Indicator
SYMPTOM
* VEHICLE THEFT ALARM INDICATOR
POSSIBLE CAUSES
- Vehicle theft alarm indicator defective
All Gauges Inoperative
SYMPTOM
* ALL GAUGES NOT OPERATING
POSSIBLE CAUSES
- BCM instrument cluster circuit output defective
- Instrument Cluster PC board defective
- DRB shows ignition unlock closed
- No response - CCD bus instrument cluster
- Body computer odometer failure
- RAM test failure
- ROM test failure
Cluster Illumination
SYMPTOM
* CLUSTER ILLUMINATION
POSSIBLE CAUSES
- No response - CCD bus instrument cluster
- Headlamp switch ground circuit defective
- Inoperative lamp defective
- Headlamp switch defective
- Junction block defective
- Dimmer switch signal circuit open
- Dimmer switch signal circuit shorted to ground
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6172
- Instrument panel lamps driver circuit shorted to ground
- Panel lamps driver circuit open
- Park lamps not lighting
- Instrument Cluster circuit board defective
- BCM dimmer switch signal circuit output faulty
- BCM defective
- BCM defective by default
- Body computer odometer failure
- BCM dimmer switch signal circuit defective
- Illumination panel fuse OK
- Inoperative lamp ground circuit
- RAM test failure
- ROM test failure
Cluster Warning Lamps Odometer and PRNDL Display
SYMPTOM
* CLUSTER WARNING LAMPS ODOMETER AND PRNDL DISPLAY
POSSIBLE CAUSES
- Any one lamp/bulb defective
- Washer fluid level switch sense circuit open
- Washer fluid level switch sense ground circuit open
- Washer fluid level switch sense circuit shorted
- Body computer odometer failure DTC
- No response - CCD bus instrument cluster
- Washer fluid level switch defective
- BCM washer fluid switch sense circuit input defective
- All segments fail to light
- Faulty odometer and PRNDL lamp
- Generator lamp failure
- Instrument cluster printed circuit board defective
Gauges Not Returning to Zero With Key Off
SYMPTOM
* GAUGES NOT GOING TO ZERO WHEN KEY IS TURNED OFF
POSSIBLE CAUSES
- Fused B(+) circuit open
- No response - CCD bus instrument cluster
- Instrument Cluster PC board defective
- Body computer odometer failure
- RAM test failure
- ROM test failure
One Gauge Not Operating Properly
SYMPTOM
* ONE GAUGE OPERATING IMPROPERLY
POSSIBLE CAUSES
- DRB reads active on the bus
- DRB reads no vehicle speed sense signal code
- IOD fuse is loose in junction block
- Speedometer calibration out
- Any one lamp/bulb defective
- DRB reading not matching RPM
- Washer fluid level switch sense circuit open
- Washer fluid level switch sense ground circuit open
- Washer fluid level switch sense circuit shorted
- Washer fluid level switch defective
- Gauge pack defective
- Speedometer/Odometer gauge pack defective
- Tachometer calibration out
- Cooling system condition faulty
- DRB reads coolant temperature sensor code
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6173
- DRB reads engine temperature accurately
- BCM instrument cluster circuit output defective
- Body Control Module defective
- Gauge pack defective
- Instrument Cluster printed circuit board defective
- DRB shows ignition unlock closed
- BCM washer fluid level switch sense circuit input defective
- All segments fail to light
- BCM temperature gauge input defective
- Faulty odometer and PRNDL lamp
- Generator lamp failure
- PCM defective
- Pinion factor failure
Trip and Rest Button(S)
SYMPTOM
* TRIP AND RESET BUTTON(S)
POSSIBLE CAUSES
- Trip & reset button(s) defective
Courtesy Lamps Inoperative W/Dome Lamp Switch
SYMPTOM
* COURTESY LAMPS INOPERATIVE W/DOME LAMP SWITCH
POSSIBLE CAUSES
- Courtesy lamp switch sense circuit open
- Headlamp switch defective - courtesy lamp function open
- BCM defective - courtesy lamp switch sense (by default)
- BCM defective - dome lamp switch function
Courtesy Lamps Inoperative With Any Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH ANY DOOR
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Courtesy lamp relay control circuit open
- Switched courtesy lamp relay control circuit open
- Junction block defective - lamp relay fused B(+) (CAV 87) open
- Courtesy lamp relay defective - coil open
- Junction block defective - lamp relay fused B(+) (CAV 30) open
- Junction block defective - lamp relay fused B(+) (CAV 86) Open
- Headlamp switch defective - open
- BCM defective - lamp relay control function (by default)
- BCM defective - driver door ajar switch status
Courtesy Lamps Inoperative With Driver Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH DRIVER DOOR
POSSIBLE CAUSES
- Driver door ajar switch defective, open
- Driver door ajar switch sense circuit open
- Left front door switch ground strap corroded/damaged
- Body Control Module inoperative, open
Courtesy Lamps Inoperative With Left Sliding Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH LEFT SLIDING DOOR
POSSIBLE CAUSES
- Left sliding door ajar switch sense circuit open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6174
- Left sliding door ajar ground circuit open
- Left sliding door ajar switch defective, open
- BCM defective
Courtesy Lamps Inoperative With Liftgate
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH LIFTGATE
POSSIBLE CAUSES
- Liftgate ground circuit open
- Liftgate ajar switch open - ajar switch disconnected
- Liftgate ajar switch sense circuit open
- BCM defective, open
Courtesy Lamps Inoperative With Passenger Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH PASSENGER DOOR
POSSIBLE CAUSES
- Passenger door ajar switch defective, open
- Passenger door ajar switch sense circuit open
- Right front door switch ground strap corroded/damaged
- Body Control Module inoperative, open
Courtesy Lamps Inoperative With Right Sliding Door
SYMPTOM
* COURTESY LAMPS INOPERATIVE WITH RIGHT SLIDING DOOR
POSSIBLE CAUSES
- Right sliding door ajar switch defective, open
- Right sliding door ajar switch sense circuit open
- Right sliding door ajar ground circuit open
- BCM defective, open
Courtesy Lamps On at All Times
SYMPTOM
* COURTESY LAMPS ON AT ALL TIME
POSSIBLE CAUSES
- No response (BCM) - CCD bus failure
- Courtesy lamp relay output circuit shorted to B(+)
- Courtesy lamp relay control circuit shorted to ground
- Switched courtesy lamp relay control circuit shorted to ground
- Courtesy lamp relay defective - coil shorted
- Headlamp switch shorted
- BCM defective - relay control shorted (by default)
Illuminated Entry Inoperative With Driver Door Key Cylinder
SYMPTOM
* ILLUMINATED ENTRY INOPERATIVE WITH DRIVER DOOR KEY CYLINDER
POSSIBLE CAUSES
- Driver door key switch unlock position stuck
- Driver door key cylinder switch defective
- Driver door key switch sticking
Illuminated Entry Inoperative With RKE Transmitter
SYMPTOM
* ILLUMINATED ENTRY INOPERATIVE WITH RKE TRANSMITTER
POSSIBLE CAUSES
- RKE circuit at BCM defective
- RKE ground circuit open
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6175
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- Defective door lock switch
- Defective unlock switch
- RKE module default replacement
- RKE module defective
CMTC Avg MPH/Fuel Economy Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER AVG MPH OR FUEL ECONOMY INOPERATIVE OR
WRONG
POSSIBLE CAUSES
- No PCM communications
- TPS inoperative
- VSS signal inoperative
CMTC Elapsed Time Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER ELAPSED TIME INOPERATIVE OR WRONG
POSSIBLE CAUSES
- Defective BCM / Indicator lights
CMTC Fails to Respond to Instrument Cluster Dimming
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER FAILS TO RESPOND TO INSTRUMENT CLUSTER
DIMMING
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer
CMTC Trip Odometer Inoperative or Wrong
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER TRIP ODOMETER INOPERATIVE OR WRONG
TEST NOTE
This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER AVG MPH OR
FUEL ECONOMY INOPERATIVE/WRONG.
POSSIBLE CAUSES
- No PCM communications
- TPS inoperative
- VSS signal inoperative
Compass/Mini-Trip Computer Displaying OC
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER DISPLAYING OC
POSSIBLE CAUSES
- Open sensor ground circuit
- Ambient Temperature Sensor defective
- Open Ambient Temperature Sensor signal circuit
- Defective Compass/Mini-Trip Module - sensor ground circuit.
Compass/Mini-Trip Computer Displaying SC
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER DISPLAYING SC
POSSIBLE CAUSES
- Defective Ambient Temperature Sensor
- Ambient Temperature Sensor signal circuit shorted to ground
- Compass/Mini-Trip Module default
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6176
Compass/Mini-Trip Computer Segments Fail to Light
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SEGMENTS FAIL TO LIGHT
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer - segments fail to light
Compass/Mini-Trip Computer Shows Failed
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SHOWS FAILED
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer - shows failed
Compass/Mini-Trip Computer Switch Inoperative
SYMPTOM
* COMPASS/MINI-TRIP COMPUTER SWITCH INOPERATIVE
TEST NOTE
This symptom is diagnosed using the test COMPASS/MINI-TRIP COMPUTER FAILS TO
RESPOND TO INSTRUMENT CLUSTER DIMMING.
POSSIBLE CAUSES
- Defective Compass/Mini-Trip Computer
Incorrect Ambient Temperature Readings
SYMPTOM
* INCORRECT AMBIENT TEMPERATURE READINGS
POSSIBLE CAUSES
- Open sensor ground - defective CMTM
- Sensor ground circuit partial short to ground
- Defective Ambient Temperature Sensor/Road test
- Ambient Temperature Sensor signal circuit partial short
- Ambient Temperature Sensor signal circuit shorted
- Defective Compass/Mini-Trip Module
- Defective Compass/Mini-Trip Module sensor ground circuit
Add'l All Doors (Exc Drvr w/RKE) Fail Lck/Unlckfrom Any Switch
SYMPTOM
ADDITIONAL ALL DOORS (EXCEPT DRVR W/RKE) FAIL LCK/UNLCK FROM ANY SWITCH
POSSIBLE CAUSES
- Junction block defective
- Door unlock relay output circuit open
- Door unlock relay output circuit resistance low
Additional All Doors (Exc Driver w/RKE) Fail to Unlock
SYMPTOM
ADDITIONAL ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK
POSSIBLE CAUSES
- Fused B(+) circuit voltage too low at junction block
- Door unlock relay control inoperative at BCM
- Door unlock relay defective
- Door unlock relay coil resistance out of tolerance
- Door unlock relay output circuit shorted to ground
Additional All Doors Fail to Lock and Unlock From Any Switch
SYMPTOM
* ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6177
POSSIBLE CAUSES
- Passenger door switch MUX shorted to battery
- Door lock switch resistance high in unlock position
- Driver door switch MUX circuit shorted to battery
- Liftgate switch MUX shorted to battery
- BCM door lock relay control circuit inoperative
- Liftgate switch MUX at BCM defective
- Door lock relay control ground circuit open
- Door lock relay defective
- Fuse # 26 defective
- Fused B(+) circuit open
- Fused B(+) circuit shorted to ground
- Ground circuit open at door lock relay connector
Additional All Doors Fail to Lock and Unlock From One Switch
SYMPTOM
ADDITIONAL ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH
POSSIBLE CAUSES
- Door key cylinder switch connector circuit ground circuit open
- Door key cylinder switch defective
- Liftgate key cylinder switch defective
- Liftgate switch MUX shorted to battery
- Door switch MUX circuit to BCM open
- Driver door switch MUX circuit open at BCM connector
- Liftgate switch MUX circuit open at BCM connector
- Liftgate switch MUX circuit to BCM open
- Passenger door switch MUX circuit open at BCM connector
- Passenger door switch MUX circuit to BCM open
- Door lock switch connector ground circuit open
- Door lock switch defective
- Door lock switch MUX circuit open
- Door locks inoperative from key cylinder switch
- Door switch MUX circuit shorted to battery
Additional All Doors Failing to Lock From Any Switch
SYMPTOM
ADDITIONAL ALL DOORS FAILING TO LOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Fused B(+) circuit voltage too low at junction block
- Door lock relay control circuit from BCM fails
- Key - in ignition switch circuit to BCM defective
- Door lock relay does not operate
- Door lock relay coil resistance out of tolerance
- Door lock relay output shorted to ground
- Ignition switch defective
- Key - in ignition switch sense circuit shorted to ground
Additional Driver Door (w/RKE) Failing to Unlock From Any SW
SYMPTOM
ADDITIONAL DRIVER DOOR (W/RKE)FAILING TO UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Driver door unlock relay coil resistance out of tolerance
- Driver door unlock relay defective
- Driver door unlock relay output circuit shorted to ground
- Voltage too low at junction block fused B(+) circuit
Additional One Door Fails to Lock and Unlock From Any Switch
SYMPTOM
ADDITIONAL ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6178
POSSIBLE CAUSES
- RKE equipped door lock fails to lock & unlock
- Door lock motor defective
- Driver unlock relay ground open in junction block
- Door lock relay output circuit open
- Door unlock relay output circuit open
- Driver door unlock relay open
All Doors (Exc Driver w/RKE) Fail Lock/Unlock From Any Switch
SYMPTOM
* ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO LOCK/UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors (Exc Driver w/RKE) Fail to Unlock
SYMPTOM
* ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO UNLOCK
POSSIBLE CAUSES
- RKE circuit at BCM defective
- RKE ground circuit open
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- Defective door lock switch
- Defective door unlock switch
- RKE module default replacement
- RKE module defective
All Doors Fail to Lock and Unlock From Any Switch
SYMPTOM
* ALL DOORS FAIL TO LOCK AND UNLOCK FROM ANY SWITCH
POSSIBLE CAUSES
- Link to body communication bus inoperative
- Defective door lock switch
- Defective unlock switch
All Doors Fail to Lock and Unlock From One Switch
SYMPTOM
* ALL DOORS FAIL TO LOCK AND UNLOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors Failing to Lock From Any Switch
SYMPTOM
* ALL DOORS FAILING TO LOCK FROM ANY SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6179
- Defective unlock switch
All Doors Failing to Lock From One Switch
SYMPTOM
* ALL DOORS FAILING TO LOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
All Doors Failing to Unlock From One Switch
SYMPTOM
* ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
Automatic Door Locks Do Not Lock Over 15 MPH
SYMPTOM
* AUTOMATIC DOOR LOCKS DO NOT LOCK OVER 15 MPH
POSSIBLE CAUSES
- Link to body communication bus inoperative
- TPS malfunction causes door lock problem
- VSS malfunction causes door lock problem
- Auto door lock not enabled
Doors Lock With Key In Ignition and Left Door Open
SYMPTOM
* DOORS LOCK WITH KEY IN IGNITION AND LEFT DOOR OPEN
POSSIBLE CAUSES
- Link to body communication bus inoperative
- BCM defective
- BCM sends wrong key - in ignition status
- BCM a connector terminals damaged
- Ignition switch open
- Key - in ignition switch ground circuit open
- Key - in ignition switch sense circuit open
Driver Door (w/RKE) Failing to Unlock From Any Switch
SYMPTOM
* DRIVER DOOR (W/RKE) FAILING TO UNLOCK FROM ANY SWITCH
TEST NOTE
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
One Door Fails to Lock and Unlock From Any Switch
SYMPTOM
* ONE DOOR FAILS TO LOCK AND UNLOCK FROM ANY SWITCH
TEST NOTE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6180
This sympton is diagnosed using the test ALL DOORS (EXCEPT DRIVER W/RKE) FAIL TO
LOCK/UNLOCK FROM ANY SWITCH.
POSSIBLE CAUSES
- Defective door lock switch
- Defective unlock switch
Remote Keyless Entry Problem
SYMPTOM
* RKE PROBLEM
POSSIBLE CAUSES
- Link to body communication bus inoperative
- RKE circuit at BCM defective
- RKE ground circuit open
- RKE fused B(+) circuit open
- RKE interface circuit open
- RKE interface circuit shorted to ground
- RKE program enable circuit open
- RKE program enable circuit shorted to ground
- RKE module default replacement
- RKE module defective
Front Wiper Operating Constantly W/Switch In Off Position
SYMPTOM
* FRONT WIPER OPERATING CONSTANTLY W/SWITCH IN OFF POSITION
POSSIBLE CAUSES
- Front wiper ON/OFF relay control circuit shorted to ground
- Defective wiper ON relay/substitute relay
- Defective multifunction switch/voltage
- High/Low wiper relay HI speed output circuit shorted to voltage
- High/Low wiper relay LO speed output circuit shorted to voltage
- Defective BCM - 100 ohms default
Front Wipers Not Parking In Off Position
SYMPTOM
* FRONT WIPERS NOT PARKING IN OFF POSITION
TEST NOTE
This symptom is diagnosed using the test FRONT WIPER PARK SWITCH CIRCUIT OPEN
POSSIBLE CAUSES
- Wiper park switch toggle closed/open
- Open wiper park switch sense circuit
- Defective BCM - wiper park switch
- Defective wiper motor/wiper park switch
Front Wipers Not Working at All
SYMPTOM
* FRONT WIPERS NOT WORKING AT ALL
POSSIBLE CAUSES
- Open wiper on relay control circuit - BCM/wiper relay
- Defective wiper ON relay - BCM/ground
- Front wiper switch MUX circuit shorted to ground
- Open front wiper switch MUX circuit between switch and BCM
- Defective High/Low wiper relay - relay connector
- Defective multifunction switch/front wiper switch
- High/Low wiper relay HI speed output circuit shorted to ground
- High/Low wiper relay LO speed output circuit shorted to ground
- Open ground circuit/lights
- Open High/Low relay LO speed output circuit between High/Low relay and wiper motor
- Open fused ignition switch output circuit/multifunction switch
- Defective Power Distribution Center - relay connector
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6181
- Defective Power Distribution Center - front wiper relay
- Defective Power Distribution Center - wiper ON relay
- Defective Power Distribution Center - wiper relay
- Defective Power Distribution Center - H/L relay
- Defective Power Distribution Center - B(+) circuit.
- Defective wiper motor/harness
- Defective BCM/wiper relay
- Defective BCM/front wiper MUX
- Defective BCM/sensors
- Defective wiper motor ground circuit.
Front Wipers Not Working In High Speed Mode
SYMPTOM FRONT WIPERS NOT WORKING IN HIGH SPEED MODE
POSSIBLE CAUSES
- Open HI/LO wiper relay control circuit
- Defective HI/LO wiper RELAY - Wiper switch
- Open wiper HI/LO relay HI speed output circuit
- Defective multi - FUNCT switch/ ground circuit
- Defective power DIST CNTR-H/L WPR RLY
- Defective wiper Motor/HI speed output circuit
- Open ground circuit/Multi - Function switch
Front Wipers Not Working In Intermittent Mode
SYMPTOM
* FRONT WIPERS NOT WORKING IN INTERMITTENT MODE
POSSIBLE CAUSES
- Defective multifunction switch/positions
- Defective BCM/wiper positions
- Defective multifunction switch/Default
Front Wipers Not Working In Low Speed Mode
SYMPTOM
* FRONT WIPERS NOT WORKING IN LOW SPEED MODE
POSSIBLE CAUSES
- High/Low wiper relay control circuit shorted to ground
- Defective High/Low wiper relay - fused ignition switch
- Open High/Low wiper relay - LO speed output circuit
- Defective wiper motor/LO speed output circuit
Rear Washer Motor Inoperative
SYMPTOM
* REAR WASHER MOTOR INOPERATIVE
POSSIBLE CAUSES
- Open rear washer motor control circuit
- Defective rear washer motor/jumper
- Open fused ignition switch output circuit/voltage
- Defective HVAC Control Module / 3.8 volts
- Defective BCM - washer motor operate
Rear Wiper Not Parking In the Off Position
SYMPTOM
* REAR WIPER NOT PARKING IN THE OFF POSITION
POSSIBLE CAUSES
- Rear wiper motor control circuit shorted to battery
- Defective HVAC Control Module/switch indicator lights
- Defective wiper motor/wiper motor connector
- Defective BCM/rear wiper motor - default
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6182
- Defective BCM/washer motor run
- Defective BCM/cycle on default
- Defective BCM/rear wiper switch voltage
- Defective rear wiper motor/test light
Rear Wiper Not Working at All
SYMPTOM
* REAR WIPER NOT WORKING AT ALL
POSSIBLE CAUSES
- Open rear wiper motor control circuit
- Open rear wiper switch MUX circuit
- Open ground circuit/rear wiper motor
- Open fused ignition switch output circuit/fuse # 6
- Open fused ignition switch output circuit/fuse # 8
- Shorted fused ignition switch output circuit/fuse # 6
- Defective rear wiper motor/motor control
- Defective HVAC Control Module/default
- Defective HVAC Control Module/rear wiper switch MUX
- Defective BCM/rear wiper switch MUX
- Defective BCM/rear wiper motor
- Defective HVAC Control Module/21-Way connector
Rear Wiper Not Working In the Intermittent Mode
SYMPTOM
* REAR WIPER NOT WORKING IN THE INTERMITTENT MODE
POSSIBLE CAUSES
- Defective rear wiper motor/intermittent switch
- Defective HVAC Control Module/indicator light
- Defective HVAC Control Module/rear wiper switch
- Defective BCM/test light default
Rear Wiper/Wash Working Continuously
SYMPTOM
* REAR WIPER/WASH WORKING CONTINUOUSLY
POSSIBLE CAUSES
- Rear wiper motor control circuit shorted to battery
- Defective wiper motor/wiper motor connector
- Defective BCM/rear wiper motor - default
- Defective BCM/washer motor run
- Defective BCM/rear wiper switch voltage
Wiper/Wash Function Not Working Properly
SYMPTOM
* WIPER/WASH FUNCTION NOT WORKING PROPERLY
POSSIBLE CAUSES
- Defective washer motor/washer pump control
- Operate wipers
- Open washer pump control circuit
- Defective multifunction switch/washer pump control
- Open fused ignition switch output circuit
- Defective junction block/BCM
- Defective junction block/block connector
- Defective BCM/junction block
- Defective BCM/stalk switch
- Fused ignition switch output circuit shorted to ground
- Open washer pump control circuit/multifunction switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6183
Body Control Module: Component Tests and General Diagnostics
Six-Step Troubleshooting Procedure
Diagnosis of the body system is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
Road Testing A Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: BEFORE ROAD TESTING A VEHICLE, BE SURE THAT ALL COMPONENTS ARE
REASSEMBLED. DURING THE TEST DRIVE, DO NOT TRY TO READ THE DRB SCREEN
WHILE IN MOTION.DO NOT HANG THE DRB FROM THE REAR VIEW MIRROR OR OPERATE
IT YOURSELF. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRB.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6184
Body Control Module: Scan Tool Testing and Procedures
Under normal operation, the DRB will display one of only two error messages: - User-Requested
WARM Boot or User-Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the MDS
Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error
message display:
ver: 2.14 date: 26 Jul93 file: keyitf.cc date: Jul 26 1993 line: 548 err: Ox1 User-Requested COLD
Boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRB III (R) Does Not Power up (Blank Screen) If the LED's do not light or no sound is emitted at
start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data
link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A.
DRB Scan Tool
Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to
compensate for this condition
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Page 6185
Body Control Module: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove lower steering column cover and
knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control
Module (BCM)
Body Control Module - Location
4. Remove bolts holding Junction Block to dash panel mounting bracket. 5. Remove Junction Block
from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide
Body Control Module downward to disengage guide studs on Junction Block from channels on
BCM mounting bracket. 8. Remove Body Control Module from Junction Block.
INSTALLATION
For installation, reverse the above procedures.
REMOVAL AND INSTALLATION
Refer to Instrument Panel and Systems, Body Control Module Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Page 6186
Body Control Module: Tools and Equipment
DRB III (R) (diagnostic read-out box w/pep module and latest software version) jumper wires
ohmmeter voltmeter oil pressure gauge (0-300 psi) test light
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair
Front Door Exterior Handle: Service and Repair
EXTERIOR HANDLE
REMOVAL
1. Roll door glass up. 2. Remove the watershield. (Refer to Front Door Panel.) 3. Through access
hole at rear of inner door panel, disconnect Vehicle Theft Security System (VTSS) switch connector
from door harness, if
equipped.
4. Disengage push in fasteners attaching VTSS switch harness to inner door reinforcement bar, if
equipped. 5. Disengage clip holding door latch linkage to door latch. 6. Remove latch linkage from
latch. 7. Disengage clip holding door lock linkage to door latch. 8. Remove lock linkage from latch.
Fig. 19
9. Remove nuts holding outside door handle to door outer panel (Fig. 19). 10. Remove outside
door handle from vehicle.
INSTALLATION
If outside door handle replacement is necessary, transfer lock cylinder from the original handle to
the new one.
1. Place outside door handle in position on vehicle. 2. Install nuts attaching outside door handle to
door outer panel (Fig. 19) . 3. Insert lock linkage into door latch. 4. Engage ,clip to hold door lock
linkage to latch. 5. Insert latch linkage into door latch. 6. Engage clip to hold door latch linkage to
latch. 7. Install push-in fasteners to hold VTSS switch harness to inner door reinforcement bar, if
equipped. 8. Connect VTSS switch connector into door harness, if equipped. 9. Verify door latch
operation.
10. Install sound shield and door trim panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor
> Component Information > Service and Repair
Front Door Window Motor: Service and Repair
WARNING: DO NOT HAVE ANY HANDS OR FINGERS IN AREA WHERE THEY CAN BE
PINCHED BY SMALL MOVEMENTS OF REGULATOR LINKAGE.
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel and sound
pad. 3. Tape the window in its existing position to remove its weight from the regulator system. 4.
Cut and remove the tie wrap at the window motor. Its no longer required. 5. Disconnect window
motor wire connector from door harness. 6. Remove screws and nuts holding window motor to the
inner panel. 7. Remove the motor from the door inner panel, let it hang from the cables. 8. With the
cables still attached to the failed motor, Install the replacement motor to the door inner panel.
Tighten down the screws and nuts to 3.4 to
4.5 Nm (30 to 40 in. lbs.) of torque.
9. Separate the failed motor from regulator by:
- Removing the drum cover plate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor
> Component Information > Service and Repair > Page 6197
Power Window Motor Removal
- Lift the cable guide off the motor, the drum with cables, will be lifted off simultaneously.
CAUTION: Do not allow the drum to separate from the cable guide, by dropping drum or letting the
cables unwind.
INSTALLATION
1. Install the cable guide and drum into the replacement motor.
CAUTION: The drum may require a slight rotation to install onto the motor drive shaft. Rotate the
drum with the use of needle nose pliers or a similar tool. If, the drum does not align with the motor
shaft by a slight rotation,then, the glass should be lowered a small amount approximately 1 to 2
inches. The drum will rotate when the glass is lowered. Lowering the glass will require assistance
of a second person.
2. Install the replacement cover plate onto the replacement motor. Crimp toy tabs. 3. Connect the
wiring harness to the window motor connector. 4. Remove the tape holding the window in place
and test window operation. 5. Re-assemble remaining parts in reverse order as above.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Service and Repair
Sliding Door Handle: Service and Repair
EXTERIOR HANDLE
REMOVAL
1. Remove sliding door trim panel. 2. Remove sliding door stop bumper. 3. Peel watershield away
from adhesive around perimeter of inner door panel as necessary to access outside release handle
fasteners. 4. Remove latch/lock control cover. 5. Disengage clip holding outside door handle
linkage to door handle. 6. Remove linkage from outside door handle. 7. Remove linkage from
latch/lock control.
Fig. 31
8. Remove nuts holding outside door handle to outer door panel (Fig. 31). 9. Remove outside door
handle from vehicle.
INSTALLATION
1. Position outside door handle on vehicle. 2. Install nuts attaching outside door handle to outer
door panel. 3. Insert linkage into outside door handle. 4. Engage clip to hold linkage to outside door
handle. 5. Engage rigging-cam to latch/lock control mechanism. 6. Move clip on latch/lock control
to bottom of slot and engage linkage to latch/lock control. 7. Verify sliding door operation. Adjust as
necessary. 8. Install latch/lock cover. 9. Place the watershield into position and press securely to
adhesive making sure to properly route wiring and linkages.
10. Install sliding door stop bumper. 11. Install sliding door trim panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood
Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood.
Negative Battery Cable
2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry
trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire
connector and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor >
Component Information > Diagrams
Liftgate Lock Motor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams
Liftgate Ajar Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications
Cross-Member: Specifications
To Body Attaching Bolts ......................................................................................................................
................................................ 163 Nm (120 ft. lbs.) Reinforcement Plate Attaching Bolts M-12
............................................................................................................................................ 108 Nm
(80 ft. lbs.) Reinforcement Plate Attaching Bolts M-14
.......................................................................................................................................... 166 Nm
(123 ft. lbs.) Cradle Plate To Cradle Attaching Bolts
............................................................................................................................................... 165 Nm
(123 ft. lbs.)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions
Console: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 6223
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Console: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Console Replacement
Console: Service and Repair Console Replacement
REMOVAL
Lower Console
1. Remove screws holding lower console to floor bracket and instrument panel. 2. Slide console
rearward from around instrument panel supports. 3. Remove lower console.
INSTALLATION
1. Place lower console in position. 2. Slide console forward around instrument panel supports. 3.
Install screws to hold lower console to floor bracket and instrument panel.
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Console: Service and Repair Convenience Bin Lamp
Unused Convenience Bin Lamp Socket Location
If the lamp is not used refer to the above image.
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Pull out and remove the convenience bin cup holder. Refer to Body and Frame/Interior Trim/Drink Holder/Convenience Bin - Cup Holder
removal.
3. Insert the trim stick (special tool #C-4755) between access cover and radio bezel, above
convenience bin - cup holder.
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Convenience Bin Access Cover
4. Carefully pry the access cover from the instrument panel. 5. Separate the access cover from the
vehicle. 6. Using needle-nose pliers, carefully squeeze the vertical metal legs of the lamp hood. 7.
Lift the lamp hood upward from the cup holder tray.
Convenience Bin Lamp Bulb
8. Carefully pull the lamp and wiring rearward from the instrument panel. 9. Pull the lamp hood from
the lamp socket.
10. Pull bulb from socket.
INSTALLATION
For installation, for reverse the above procedures.
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Console: Service and Repair Convenience Bin Track
REMOVAL
1. Remove the convenience bin - cup holder. Refer to Convenience Bin - Cup Holder Replacement.
Convenience Bin Access Cover
2. Remove the screw access cover from the bottom of the radio bezel. 3. Remove the center bezel.
Convenience Bin Track
4. Remove the convenience bin track attaching screws and pull the convenience bin track rearward
to disengage the rear guide studs from instrument
panel.
5. Disengage the clip holding convenience bin lamp to track 6. Remove the convenience bin track.
INSTALLATION
For installation, reverse the above procedures.
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Console: Service and Repair Demagnetizing Procedure
A magnetic field can adversely affect the compass. Magnetic interference can magnetize the roof
panel. Magnetizing can be caused by placing a permanent magnet in contact with the roof panel.
Example:
- Magnetic Base Antenna
- Magnetic screwdriver
- Audio speakers
- Refrigerator magnets.
- Pizza Signs
- Bubble gum flasher lights
Removing magnetic interfering objects will usually restore normal compass operation. If the
compass display remains blank while the CAL label is illuminated, then the roof panel requires
demagnetizing. To demagnetize use Special Tool 6029 for demagnetizing the roof panel. The
demagnetizing procedure will demagnetize the roof and mounting screws in the overhead console.
It is important that you follow the instructions below exactly.
The mounting screws and the mounting brackets around the compass area are steel, and therefore
aid in the demagnetizing of the roof panel.
1. Be sure the ignition switch is in the OFF position before you begin the demagnetize procedure.
2. Plug the demagnetizing tool into a standard 110/115 volt AC outlet, keeping the demagnetizing
tool at least 12 inches away from the compass area
when plugging it in.
3. Slowly approach and contact the console mounting screw with the plastic coated tip of the tool
for at least two seconds. 4. With the demagnetizing tool still energized, slowly back it away from the
screw until the tip is at least 12 inches from the screw head. 5. Repeat the last step with all the
console mounting screws. 6. After you have pulled at least 12 inches from the last screw, remove
the demagnetizing tool from inside vehicle and disconnect it from the
electrical outlet.
7. Place an 8 1/2 X 11 inch piece of paper lengthwise on the roof of vehicle directly above
compass. The purpose of the paper is to protect the roof
panel from scratches and define the area to be demagnetized.
8. Plug in the demagnetizing tool, keeping it at least two feet away from the compass unit. 9. Slowly
approach the center of the roof panel at the windshield with the demagnetizing tool plugged in.
10. Contact the roof panel with the tip of the tool. Using slow sweeping motions of 1/2 inch between
sweeps. Move the tool approximately four inches
either side of the center line and at least 11 inches back from the windshield.
11. With the demagnetizing tool still energized, slowly back away from the roof panel until the tip is
at least two feet from the roof before unplugging
the tool.
12. Recalibrate compass, refer to the compass calibration procedure.
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Console: Service and Repair Overhead Console Replacement
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable.
Overhead Console
2. Open the transmitter bin door. 3. Remove screw holding the overhead console to the headliner.
With the screw removed the console is retained by one engagement tab located
inside the eyeglass storage bin.
4. Open the eyeglass bin door. 5. Press the retaining tab which is located directly above the door
latch. 6. Lower rear of console away from headliner. 7. Pull console rearward to disengage clips
holding front of console to roof armature and lower console. 8. Disconnect wire connectors from
back of CMTC and reading lamps. Ensure the connectors lock tabs are fully depressed before
disconnecting. 9. Remove overhead console.
INSTALLATION
For installation, reverse the above procedures.
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Degausser 6029
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Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS
.
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Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
Negative Battery Cable
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering
column and at the lower edge of the lower instrument
panel.
2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the
proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative
terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and
record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any
diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper
Body
Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes
on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to
diagnose the problem.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information >
Service and Repair
Drink Holders: Service and Repair
REMOVAL
Convenience Bin - Cup Holder
1. Pull the convenience bin open. 2. Push lock tab at rear center downward. 3. Pull the
convenience bin - cup holder from track in instrument panel. 4. Remove convenience bin - cup
holder.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock
> Component Information > Service and Repair
Glove Compartment Lock: Service and Repair
REMOVAL
Glove Box Lamp Striker
1. Open glove box door. 2. Disengage clip holding checkstraps to glove box door. 3. Remove
screws holding lock striker to instrument panel. 4. Remove glove box lock striker.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical
Service Bulletins > Customer Interest: > 23-33-99 > Aug > 99 > Right Side Sliding Door Trim Panel - Rubs Quarter Panel
Trim Panel: Customer Interest Right Side Sliding Door Trim Panel - Rubs Quarter Panel
NUMBER: 23-33-99
GROUP: Body
DATE: Aug. 13, 1999
SUBJECT: Right Side Sliding Door Trim Panel Rubs Quarter Panel
OVERVIEW: This bulletin involves replacing the two top center sliding door trim panel clips.
MODELS:
1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES VEHICLES BUILT PRIOR TO JULY 15, 1999 (MDH 0715XX).
SYMPTOM/CONDITION: The right side sliding door trim panel contacts the quarter panel when the
door is opened because the two top center sliding door trim panel clips do not retain the trim panel
to the door tight enough.
DIAGNOSIS: Open the right sliding door, if there is contact between the sliding door trim panel and
the quarter panel, perform the Repair Procedure.
PARTS REQUIRED:
2 06505292AA Clip, Trim Panel
AR (1) 04796237 Cleaner/Wax
EQUIPMENT REQUIRED:
Fiber Stick
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1.
Using a fiber stick remove the right side sliding door upper frame molding.
2. Remove the three screws attaching the trim panel to the door.
3. Disengage the clips around the perimeter of the trim panel that hold the trim panel to the door
with a fiber stick.
4. Remove the top two center clips from the trim panel and the top two center clip grommets from
the door.
5. Install the revised clips, p/n 06505292AA to the trim panel.
6. Place the trim panel in position on the vehicle.
7. Align the locating pins on the backside of the trim panel to the mating holes in the inner door
panel.
8. Engage the clips to hold the trim panel to the door.
9. Install the three screws that attach the trim panel to the door.
10. Install the upper frame molding.
11. If the paint is scuffed use Mopar Cleaner/Wax, p/n 04796237, to polish the paint.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical
Service Bulletins > Customer Interest: > 23-33-99 > Aug > 99 > Right Side Sliding Door Trim Panel - Rubs Quarter Panel >
Page 6270
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-20-23-94 0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 23-33-99 > Aug > 99 > Right Side Sliding Door Trim Panel - Rubs
Quarter Panel
Trim Panel: All Technical Service Bulletins Right Side Sliding Door Trim Panel - Rubs Quarter
Panel
NUMBER: 23-33-99
GROUP: Body
DATE: Aug. 13, 1999
SUBJECT: Right Side Sliding Door Trim Panel Rubs Quarter Panel
OVERVIEW: This bulletin involves replacing the two top center sliding door trim panel clips.
MODELS:
1999 - 2000 (NS) Town & Country/Caravan/Voyager 1999 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES VEHICLES BUILT PRIOR TO JULY 15, 1999 (MDH 0715XX).
SYMPTOM/CONDITION: The right side sliding door trim panel contacts the quarter panel when the
door is opened because the two top center sliding door trim panel clips do not retain the trim panel
to the door tight enough.
DIAGNOSIS: Open the right sliding door, if there is contact between the sliding door trim panel and
the quarter panel, perform the Repair Procedure.
PARTS REQUIRED:
2 06505292AA Clip, Trim Panel
AR (1) 04796237 Cleaner/Wax
EQUIPMENT REQUIRED:
Fiber Stick
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1.
Using a fiber stick remove the right side sliding door upper frame molding.
2. Remove the three screws attaching the trim panel to the door.
3. Disengage the clips around the perimeter of the trim panel that hold the trim panel to the door
with a fiber stick.
4. Remove the top two center clips from the trim panel and the top two center clip grommets from
the door.
5. Install the revised clips, p/n 06505292AA to the trim panel.
6. Place the trim panel in position on the vehicle.
7. Align the locating pins on the backside of the trim panel to the mating holes in the inner door
panel.
8. Engage the clips to hold the trim panel to the door.
9. Install the three screws that attach the trim panel to the door.
10. Install the upper frame molding.
11. If the paint is scuffed use Mopar Cleaner/Wax, p/n 04796237, to polish the paint.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 23-33-99 > Aug > 99 > Right Side Sliding Door Trim Panel - Rubs
Quarter Panel > Page 6276
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-20-23-94 0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Trim Panel: > NHTSA99V116000 > May > 99 > Recall 99V116000:
Headlamp Module Defect
Headlamp Control Module: All Technical Service Bulletins Recall 99V116000: Headlamp Module
Defect
Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL"
as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment."
These vehicles do not comply with requirements of FMVSS No. 108.
All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters.
Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on
an agreed upon service date and do not receive the free remedy within a reasonable time should
contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension
Trim Panel: Service and Repair A-Pillar Lower Extension
A-PILLAR LOWER EXTENSION TRIM
REMOVAL
1. Remove instrument panel side cover.
2. Remove screw holding A-pillar extension to door hinge pillar.
3. Separate A-pillar extension trim from vehicle A-pillar.
INSTALLATION
1. Place A-pillar extension trim in position on vehicle.
2. Install screw to hold A-pillar extension to door hinge pillar.
3. Install instrument panel side cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6289
Trim Panel: Service and Repair A-Pillar Trim
A-PILLAR TRIM PANEL
REMOVAL
1. Disengage hidden clips holding A-pillar trim panel to A-pillar.
2. Separate A-pillar trim from vehicle.
INSTALLATION
1. Position foot on A-pillar trim panel into instrument panel top cover channel.
2. Position A-pillar trim in vehicle.
3. Align locator pins.
4. Engage hidden clips.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6290
Trim Panel: Service and Repair Cowl Trim
COWL TRIM
REMOVAL
1. Remove door sill plate.
2. Disengage hidden clips holding cowl trim to cowl panel.
3. Separate cowl trim from vehicle.
INSTALLATION
1. Place cowl trim sill plate in position on vehicle.
2. Engage hidden clips to hold cowl trim to cowl panel.
3. Install door sill plate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6291
Trim Panel: Service and Repair Front Door Sill Plate
FRONT DOOR SILL PLATE
REMOVAL
1. Using trim stick, disengage hidden clips holding door sill plate from door sill.
2. Separate sill plate from vehicle.
INSTALLATION
1. Place sill plate in position on vehicle.
2. Align locating pins on backside of trim plate to mating holes in door sill.
3. Engage hidden clips to hold door sill plate to door sill.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6292
Trim Panel: Service and Repair
A-Pillar Lower Extension
A-PILLAR LOWER EXTENSION TRIM
REMOVAL
1. Remove instrument panel side cover.
2. Remove screw holding A-pillar extension to door hinge pillar.
3. Separate A-pillar extension trim from vehicle A-pillar.
INSTALLATION
1. Place A-pillar extension trim in position on vehicle.
2. Install screw to hold A-pillar extension to door hinge pillar.
3. Install instrument panel side cover.
A-Pillar Trim
A-PILLAR TRIM PANEL
REMOVAL
1. Disengage hidden clips holding A-pillar trim panel to A-pillar.
2. Separate A-pillar trim from vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6293
INSTALLATION
1. Position foot on A-pillar trim panel into instrument panel top cover channel.
2. Position A-pillar trim in vehicle.
3. Align locator pins.
4. Engage hidden clips.
Cowl Trim
COWL TRIM
REMOVAL
1. Remove door sill plate.
2. Disengage hidden clips holding cowl trim to cowl panel.
3. Separate cowl trim from vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6294
INSTALLATION
1. Place cowl trim sill plate in position on vehicle.
2. Engage hidden clips to hold cowl trim to cowl panel.
3. Install door sill plate.
Front Door Sill Plate
FRONT DOOR SILL PLATE
REMOVAL
1. Using trim stick, disengage hidden clips holding door sill plate from door sill.
2. Separate sill plate from vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6295
INSTALLATION
1. Place sill plate in position on vehicle.
2. Align locating pins on backside of trim plate to mating holes in door sill.
3. Engage hidden clips to hold door sill plate to door sill.
Front Door Trim Panel
REMOVAL
1. Using a trim stick (C-4755), pry courtesy lamp from door trim. 2. Disconnect wire connector from
courtesy lamp. 3. If equipped, remove screws attaching door assist handle to inner door panel. 4. If
equipped, remove screw attaching door pull cup to inner door panel. 5. If equipped, remove screws
attaching trim panel to door from below map pocket. 6. If equipped, remove window crank. 7. Using
a trim stick, remove screw cover from switch panel. 8. Remove screws attaching switch panel to
door trim.
Fig.32 Front Door Switch Panel
9. Remove power accessary switch from door trim.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6296
10. Disconnect power switch from wire connector.
Fig.33 Memory Seat/Mirror Switch
11. If equipped, using a small, flat bladed pry tool, remove memory seat/mirror switch and
disconnect wire connector. 12. If equipped, remove screw holding door trim to door panel from
behind inside latch release handle.
Fig.34 Front Door Trim Panel
13. Disengage clips attaching door trim to door frame around perimeter of panel. 14. Lift trim panel
upward to disengage flange from inner belt molding at top of door. 15. Tilt top of trim panel away
from door to gain access to latch linkage.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6297
Fig.35 Inside Door Handle Linkage
16. Disengage clip attaching linkage rod to inside latch release handle. 17. Separate linkage rod
from latch handle. 18. Remove front door trim panel from vehicle.
INSTALLATION
1. Hold top of trim panel away from door to gain access to latch linkage. 2. Place linkage rod in
position on latch handle. 3. Engage clip to hold linkage rod to inside latch release handle. 4. Place
front door trim panel in position on door. 5. Install trim panel into inner belt molding at top of door.
6. Install clips to attach door trim to door frame around perimeter of panel. 7. If equipped, install
screw to attach door trim to door panel behind inside latch release handle. 8. If equipped, connect
power switch into wire connector. 9. Place power accessary switch in position on door trim.
10. Connect wire connector into memory seat/mirror switch and install switch into trim panel. 11.
Install screws to attach accessary switch panel to door trim. 12. Install screw cover into switch
panel. 13. If equipped, install window crank. 14. If equipped, install screws to attach trim panel to
door inside map pocket. 15. If equipped, install screw to attach door pull cup to inner door panel.
16. If equipped, install screws to attach door assist handle to inner door panel. 17. Connect wire
connector into courtesy lamp. 18. Install lamp in door trim.
Left D-Pillar Trim Panel
LEFT D-PILLAR TRIM PANEL
REMOVAL
1. Remove rear header trim cover.
2. Remove liftgate sill plate.
3. Remove second rear seat belt turning loop on long wheel base vehicle.
4. Remove bolt holding second rear seat belt lower anchor to quarter on short wheel base vehicle.
5. Remove jack storage cover.
6. Remove screws holding trim panel to D-pillar
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6298
Left Quarter and D-Pillar Trim Panels - LWB 3 Door,
Left Quarter and D-Pillar Trim Panels - LWB 4 Door
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6299
Left Quarter and D-Pillar Trim Panels - SWB
7. Disengage hidden clips holding trim to D-pillar.
8. Disengage speaker wire connector, if equipped.
9. Pass seat belt through slot in D-pillar trim panel on short wheel base vehicle.
10. Separate D-pillar trim from vehicle.
INSTALLATION
1. Pass seat belt through slot in D-pillar trim panel on short wheel base vehicle.
2. Position D-pillar trim panel on vehicle.
3. Engage speaker wire connector to speaker, if equipped.
4. Align locating pins on backside of trim panel to mating holes in inner quarter panel.
5. Engage hidden clips to hold trim to D-pillar.
6. Install screws to hold trim to D-pillar.
7. Install jack storage cover.
8. Install bolt to hold second rear seat belt lower anchor to quarter on short wheel base vehicle.
9. Install second rear seat belt turning loop on long wheel base vehicle.
10. Install liftgate sill plate.
11. Install rear header trim cover.
Quarter Trim Bolster
QUARTER TRIM BOLSTER
The speaker grille in the quarter trim bolster is not removable. The trim bolster must removed to
service the speaker.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6300
REMOVAL
1. Disengage hidden clips holding trim bolster to quarter trim panel.
2. Disengage hook retainer holding front of trim bolster to quarter trim panel, if applicable.
3. Separate quarter trim bolster from vehicle.
Left Quarter Trim Bolster - LWB 4 Door
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6301
Left Quarter Trim Bolster SWB and LWB 3 Door
INSTALLATION
1. Place quarter trim bolster in position on vehicle.
2. Engage hook retainer to hold front of trim bolster to quarter trim panel, if applicable.
3. Engage hidden clips to hold trim bolster to quarter trim panel.
Right D-Pillar Trim Panel
RIGHT D-PILLAR TRIM PANEL
REMOVAL
1. Remove rear header trim cover.
2. Remove liftgate Sill plate.
3. Remove second rear seat belt turning loop on long wheel base vehicle.
4. Remove bolt holding second rear seat belt, if equipped, anchor to quarter on short wheel base
vehicle.
5. Remove quarter trim bolster on short wheel base vehicle.
6. Remove screws holding trim panel to attaching bracket on short wheel base vehicle.
7. Disengage hidden clips holding trim to D-pillar.
8. Separate D-pillar trim panel from D-pillar.
9. Disengage speaker wire connector, if equipped.
10. Pass second rear seat belt, if equipped, through slot in trim panel on short wheel base vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6302
11. Separate D-pillar trim from vehicle.
Right Quarter and D-Pillar Trim Panels - SWB
Right Quarter and D-Pillar Trim Panels - LWB with out A/C
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > A-Pillar Lower Extension > Page 6303
Right Quarter and D-Pillar Trim Panels - LWB with A/C
INSTALLATION
1. Position D-pillar trim on vehicle.
2. Pass second rear seat belt, if equipped, through slot in trim panel on short wheel base vehicle.
3. Engage speaker wire connector to speaker, if equipped.
4. Align locating pins on backside of trim panel to mating holes in D-pillar.
5. Engage hidden clips to hold trim to D-pillar.
6. Install screws to hold trim panel to attaching bracket on short wheel base vehicle.
7. Install quarter trim bolster on short wheel base vehicle.
8. Install bolt to hold second rear seat belt, if equipped, anchor to quarter on short wheel base
vehicle.
9. Install second rear seat belt turning loop on long wheel base vehicle.
10. Install liftgate sill plate.
11. Install rear header trim cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams
Remote Keyless Entry (RKE) Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Page 6309
Keyless Entry Module: Adjustments
The content of this article reflects the changes called out by TSB 26-09-99.
PROGRAMMING RKE MODULE
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the
transmitter at the same time. Then press any one of
the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of
the transmitter has been completed and was successful.
7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8.
Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the
ignition OFF. A single chime will sound to verify
that the RKE module will no longer accept additional Vehicle Access Code(s).
9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF
position and verify RKE system operation using each
key fob.
NOTE: Only the two key fob transmitters that have been programmed to the memory seat and
mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will
require programming.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Page 6310
Keyless Entry Module: Service and Repair
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer
to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws
holding RKE module to instrument panel.
RKE Module
4. Disconnect wire connector from RKE module.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Programming Connector >
Component Information > Locations
Remote Keyless Entry (RKE) Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry
Transmitter Battery > Component Information > Specifications
Keyless Entry Transmitter Battery: Specifications
The batteries can be removed without special tools and are readily available at local retail stores.
The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years.
CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary.
Hands must be clean and dry.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-042-00 > Nov > 00 >
Sliding Door Power Lock Actuator - Chatter Sound
Power Door Lock Actuator: Customer Interest Sliding Door Power Lock Actuator - Chatter Sound
NUMBER: 23-042-00
GROUP: Body
DATE: Nov. 3, 2000
SUBJECT: Sliding Door Power Lock Actuator Chatter Sound
OVERVIEW: This bulletin involves installing a rubber 0-ring on the sliding door lock lever tab to
eliminate the plunger lifting away from the lock lever when in the lock position.
MODELS: 1996 - 2000
(NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
SYMPTOM/CONDITION:
A chatter sound may be heard coming from the sliding door power lock actuator(s) when the power
lock feature is repeatedly activated.
DIAGNOSIS:
Use the power door lock switch to perform an unlock - lock - lock cycle, repeat the cycle three
times, if a chatter sound is heard at one or both of the sliding door actuators, perform the Repair
Procedure.
NOTE:
REPEATING THE TEST MORE THAN 3 TIMES MAY TRIP THE POSITIVE TEMPERATURE
COEFFICIENT (PTC) CIRCUIT AND CAUSE THE CHATTER SOUND; CHATTER DUE TO
TRIPPING OF THE PTC IS NOT CONSIDERED A FAILURE. IF THE PTC CIRCUIT HAS
TRIPPED, WAIT ONE HOUR BEFORE RETRYING THE DIAGNOSIS.
PARTS REQUIRED:
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Remove the sliding door interior trim panel using the procedure outlined on page 23-52 of the
2000 Town & Country/Caravan/Voyager Service Manual (Publication No.81-370-0005 and
available on MDS2).
2. Carefully peel back the water shield to expose the plastic cover over the latch/lock control.
3. Remove the latch/lock control cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-042-00 > Nov > 00 >
Sliding Door Power Lock Actuator - Chatter Sound > Page 6327
4. Replace the lock actuator grommet (Fig. 1), with the one included in kit p/n 05072507AA.
5. Install the 0-ring from kit p/n 05072507AA, over the lock lever tab and against the actuator
grommet as shown in (Fig. 1).
6. Test by performing an unlock - lock - lock cycle, repeat the cycle three times. No chatter should
be heard from the actuator and the plunger should remain held under the lock lever during and
after actuation.
7. Install the latch/lock control cover.
8. Install the water shield.
9. Install the sliding door interior trim panel.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-03-99 > Feb > 99 >
Power Door Lock Motor - Whirling Noise
Power Door Lock Actuator: Customer Interest Power Door Lock Motor - Whirling Noise
NUMBER: 23-03-99
GROUP: Body
DATE: Feb. 12, 1999
SUBJECT: Power Door Lock Motor Whirling Noise
MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
DISCUSSION: Some front and/or sliding door power lock motors may make a whirling noise after
the lock actuator has reached its full travel. Sometimes the wrong door power lock motor is
replaced because of poor diagnosis procedures. The following diagnosis procedure is provided to
help improve Fix It Right (FIR) scores.
1. With all vehicle doors open, activate the power door locks a minimum of five times repeatedly
locking and then a minimum of five times repeatedly unlocking to discover any power door lock
motors that make a whirling noise, even intermittently.
2. If a noisy power door lock motor is heard, determine which side is producing the whirling noise
by placing your ear near the rear of the suspect front door, then activate the power door locks to
confirm which side the whirling noise is coming from.
3. If the front door power lock motor/latch(s) is found to be noisy, Replace it using the procedures
outlined on page 23-40 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
4. If the whirling noise was not heard in step 1, close the left sliding door (leave the front doors
open) and activate the door locks a minimum of five times repeatedly locking and then a minimum
of five times repeatedly unlocking.
5. If the whirling noise is heard replace the left sliding door latch/lock control using the procedures
outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
6. If the noise is not heard in step 4, open the left sliding door and close the right sliding door.
(leave the front doors open) Activate the door locks a minimum of five times repeatedly locking and
then a minimum of five times repeatedly unlocking.
7. If the whirling noise is heard replace the right sliding door latch/lock control using the procedures
outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
POLICY: Reimbursable within the provisions of the warranty. Refer to the appropriate Labor
Operation Time Schedule for operation number, time allowance and failure code.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-042-00 > Nov
> 00 > Sliding Door Power Lock Actuator - Chatter Sound
Power Door Lock Actuator: All Technical Service Bulletins Sliding Door Power Lock Actuator Chatter Sound
NUMBER: 23-042-00
GROUP: Body
DATE: Nov. 3, 2000
SUBJECT: Sliding Door Power Lock Actuator Chatter Sound
OVERVIEW: This bulletin involves installing a rubber 0-ring on the sliding door lock lever tab to
eliminate the plunger lifting away from the lock lever when in the lock position.
MODELS: 1996 - 2000
(NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
SYMPTOM/CONDITION:
A chatter sound may be heard coming from the sliding door power lock actuator(s) when the power
lock feature is repeatedly activated.
DIAGNOSIS:
Use the power door lock switch to perform an unlock - lock - lock cycle, repeat the cycle three
times, if a chatter sound is heard at one or both of the sliding door actuators, perform the Repair
Procedure.
NOTE:
REPEATING THE TEST MORE THAN 3 TIMES MAY TRIP THE POSITIVE TEMPERATURE
COEFFICIENT (PTC) CIRCUIT AND CAUSE THE CHATTER SOUND; CHATTER DUE TO
TRIPPING OF THE PTC IS NOT CONSIDERED A FAILURE. IF THE PTC CIRCUIT HAS
TRIPPED, WAIT ONE HOUR BEFORE RETRYING THE DIAGNOSIS.
PARTS REQUIRED:
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Remove the sliding door interior trim panel using the procedure outlined on page 23-52 of the
2000 Town & Country/Caravan/Voyager Service Manual (Publication No.81-370-0005 and
available on MDS2).
2. Carefully peel back the water shield to expose the plastic cover over the latch/lock control.
3. Remove the latch/lock control cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-042-00 > Nov
> 00 > Sliding Door Power Lock Actuator - Chatter Sound > Page 6337
4. Replace the lock actuator grommet (Fig. 1), with the one included in kit p/n 05072507AA.
5. Install the 0-ring from kit p/n 05072507AA, over the lock lever tab and against the actuator
grommet as shown in (Fig. 1).
6. Test by performing an unlock - lock - lock cycle, repeat the cycle three times. No chatter should
be heard from the actuator and the plunger should remain held under the lock lever during and
after actuation.
7. Install the latch/lock control cover.
8. Install the water shield.
9. Install the sliding door interior trim panel.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-03-99 > Feb
> 99 > Power Door Lock Motor - Whirling Noise
Power Door Lock Actuator: All Technical Service Bulletins Power Door Lock Motor - Whirling Noise
NUMBER: 23-03-99
GROUP: Body
DATE: Feb. 12, 1999
SUBJECT: Power Door Lock Motor Whirling Noise
MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
DISCUSSION: Some front and/or sliding door power lock motors may make a whirling noise after
the lock actuator has reached its full travel. Sometimes the wrong door power lock motor is
replaced because of poor diagnosis procedures. The following diagnosis procedure is provided to
help improve Fix It Right (FIR) scores.
1. With all vehicle doors open, activate the power door locks a minimum of five times repeatedly
locking and then a minimum of five times repeatedly unlocking to discover any power door lock
motors that make a whirling noise, even intermittently.
2. If a noisy power door lock motor is heard, determine which side is producing the whirling noise
by placing your ear near the rear of the suspect front door, then activate the power door locks to
confirm which side the whirling noise is coming from.
3. If the front door power lock motor/latch(s) is found to be noisy, Replace it using the procedures
outlined on page 23-40 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
4. If the whirling noise was not heard in step 1, close the left sliding door (leave the front doors
open) and activate the door locks a minimum of five times repeatedly locking and then a minimum
of five times repeatedly unlocking.
5. If the whirling noise is heard replace the left sliding door latch/lock control using the procedures
outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
6. If the noise is not heard in step 4, open the left sliding door and close the right sliding door.
(leave the front doors open) Activate the door locks a minimum of five times repeatedly locking and
then a minimum of five times repeatedly unlocking.
7. If the whirling noise is heard replace the right sliding door latch/lock control using the procedures
outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
POLICY: Reimbursable within the provisions of the warranty. Refer to the appropriate Labor
Operation Time Schedule for operation number, time allowance and failure code.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Page 6342
Power Door Lock Actuator: Diagrams
Driver Door Lock Motor
Passenger Door Lock Motor
Right (Rear) Sliding Door Lock Motor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Page 6343
Power Door Lock Actuator: Testing and Inspection
Verify battery condition before testing door lock motor(s), refer to Battery for proper diagnosis
procedures.
To determine which motor is faulty, check each individual door for electrical lock and unlock or
disconnect the motor connectors one at a time, while operating the door lock switch. In the event
that none of the motors work, the problem may be caused by a shorted motor, a relay or a bad
switch. Disconnecting the defective motor will allow the others to work.
Door Lock Motor Connector Pin Location
Front Door Lock Motor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Page 6344
Lift Gate Release Assembly
To test an individual door lock motor, disconnect the electrical connector from the motor. To lock
the door, connect a 12 volt power source to the positive pin of the lock motor and a ground wire to
the other pin. To unlock the door reverse the wire connections at the motor pin terminals. If these
results are NOT obtained, replace the motor.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Service and Repair > Liftgate Lock Motor
Power Door Lock Actuator: Service and Repair Liftgate Lock Motor
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the negative battery cable. 2. Remove liftgate trim panel.
Liftgate Lock Motor
3. Remove bolts holding liftgate lock motor to liftgate. 4. Disconnect the wire connector from power
lock motor. 5. Disconnect the liftgate lock motor from outside handle lock link. 6. Remove the
liftgate lock motor from vehicle.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Service and Repair > Liftgate Lock Motor > Page 6347
Power Door Lock Actuator: Service and Repair Sliding Door Lock Motor
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the negative battery cable. 2. Remove sliding door trim panel. 3. Remove
sound pad as necessary 4. Remove latch/lock control cover. 5. Remove latch/lock control.
Sliding Door Lock Motor
6. Remove screws holding door lock motor to latch/lock control. 7. Remove lock motor from control.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information
> Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information
> Locations > Page 6351
Power Door Lock Relay: Diagrams
Junction Block
Door Lock Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information
> Locations > Page 6352
Door Unlock Relay
Driver Door Unlock Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Diagrams
Power Door Lock Switch: Diagrams
Driver Door Lock Switch
Passenger Door Lock Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Diagrams > Page 6356
Power Door Lock Switch: Testing and Inspection
1. Remove door lock/power window switch bezel assembly from door. Refer to Power Door Lock
Switch Replacement. 2. Disconnect wire connector from back of door lock switch. 3. Depress
switch to LOCK position.
Door Lock Switch
Door Lock Switch Test
4. Using an ohmmeter, test switch resistance between Pins 2 and 3. Refer to Door Lock Switch
Test. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. If
resistance values are not within the parameters shown replace the door lock switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Diagrams > Page 6357
Power Door Lock Switch: Service and Repair
The Power Door Lock Switch is the only serviceable part on the power door lock / window switch
bezel.The window switches, window lock - out, and power vent window switch is serviced with the
bezel.
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the negative battery cable. 2. Open left door, remove screw cover near
inside door release handle. 3. Remove two screws to door lock / window switch bezel. One under
the screw cover removed in previous step and one to the rear of the front door
vent opening.
4. Pull out and up on bezel to release from door trim panel. 5. Disconnect door lock switch
connector. 6. Remove two door lock switch retaining screws and remove switch from vehicle.
INSTALLATION
1. For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description
and Operation
Heated Element: Description and Operation
Heated Mirror
Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only. The
heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the
rear window defogger is ON.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description
and Operation > Page 6362
Heated Element: Testing and Inspection
Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only. The
heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the
rear window defogger is ON.
TEST PROCEDURE 1. The mirror should be warm to the touch. 2. If not, check the 10 amp fuse
(12) in the junction block behind the instrument panel to the left of the steering column. 3. Test
voltage at rear window defogger switch.
- If no voltage repair wire.
Power Mirror Test
- Apply voltage to one wire and ground the other. Mirror should become warm to the touch.
- If not remove mirror glass and test the wires for continuity. If no continuity repair wires.
- If wires are OK, replace mirror glass.
- To test defogger switch refer to Electrically Heated Systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and
Inspection
Power Mirror Motor: Testing and Inspection
1. Remove Power Mirror Switch. Refer to Instrument Panel and Systems, Power Mirror Switch
Replacement. 2. Disconnect wiring harness connector to the power mirror switch and headlamp
switch. 3. Using two jumper wires:
- Connect one to a 12-volt source
- Connect the other to a good body ground
Power Mirror Test
- Refer to the Mirror Test Chart for wire hookups at the switch connector.
4. If results shown in table are not obtained, check for broken or shorted circuit, or replace mirror
assembly as necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and
Inspection
Power Mirror Switch: Testing and Inspection
1. Remove power mirror switch. Refer to Instrument Panel and Systems for Replacement
Procedures. 2. Disconnect wiring harness at switch connector.
Mirror Switch Test
3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in
the table are not obtained, replace the switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and
Repair > Power Mirror Switch
Power Mirror Switch: Service and Repair Power Mirror Switch
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to
Instrument Cluster Bezel Replacement.
Power Mirror Switch
3. Disconnect wire connector from back of power mirror switch. 4. Disengage lock tabs above and
below the mirror switch. 5. Pull power mirror switch from headlamp switch bezel. The power mirror
switch bezel is mounted to the bottom of the instrument cluster bezel. 6. Remove power mirror
switch.
INSTALLATION
For installation, reverse the above procedures.
REMOVAL AND INSTALLATION
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and
Repair > Power Mirror Switch > Page 6371
Power Mirror/Window Switch
Refer to Instrument Panel and Systems for service procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and
Repair > Power Mirror Switch > Page 6372
Power Mirror Switch: Service and Repair Power Mirror Switch Lamp
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to
Instrument Cluster Bezel Replacement. 3. Remove instrument cluster bezel.
Power Mirror Switch Lamp
4. Rotate bulb socket counterclockwise one quarter turn. 5. Pull bulb socket from back of power
mirror switch.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams
Remote Keyless Entry (RKE) Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 6377
Keyless Entry Module: Adjustments
The content of this article reflects the changes called out by TSB 26-09-99.
PROGRAMMING RKE MODULE
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Thrn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press and release the "LOCK" and "UNLOCK" buttons on the
transmitter at the same time. Then press any one of
the buttons. The BCM will sound an abbreviated chime to acknowledge that the programming of
the transmitter has been completed and was successful.
7. Repeat step 6 for all transmitters that will be used with this vehicle (up to 4 total). 8.
Programming mode will last for 30 seconds. To get out of programming mode sooner, turn the
ignition OFF. A single chime will sound to verify
that the RKE module will no longer accept additional Vehicle Access Code(s).
9. When Vehicle Access Code(s) programming is complete, turn the ignition switch to the OFF
position and verify RKE system operation using each
key fob.
NOTE: Only the two key fob transmitters that have been programmed to the memory seat and
mirror system will operate it. if any key fob is replaced, the memory seat and mirror module will
require programming.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 6378
Keyless Entry Module: Service and Repair
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer
to Instrument Panel and Systems, Instrument Panel Top Cover Replacement. 3. Remove screws
holding RKE module to instrument panel.
RKE Module
4. Disconnect wire connector from RKE module.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 6382
Power Door Lock Relay: Diagrams
Junction Block
Door Lock Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 6383
Door Unlock Relay
Driver Door Unlock Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Technical Service Bulletins > Memory Power Seat - Travel Range
Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range
NO: 08-44-98
GROUP: Electrical
DATE: Dec. 11, 1998
SUBJECT: Memory Power Seat Travel Range
MODELS:
1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand
Cherokee 1996-1998 (ZG) Grand Cherokee (International Market)
DISCUSSION:
The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and
remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in
MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the
motor end, fails to change. The feedback voltage potentiometers vary the position sensing
feedback voltage based on seat position/movement (no movement, no change in position sensing
feedback voltage). The seat motor automatically stops at the soft stop on any subsequent
movement so the motor does not run into a stall condition (end of travel).
The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when
something is stuck under or behind the seat that causes the seat to stop moving). These soft stops
can prevent the seat from being able to have memory positions set over the full range of travel.
Also, positions that were previously programmed to locations beyond an updated soft stop limit will
not be recalled as they are "out of range."
When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed
into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure
to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat
operation.
There are two potential reasons for intermittent memory functioning of the seats. The first
possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned
by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in
the seat's path or a person shifting their body while a power seat motor is in operation.)
The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can
be caused by a poor connection at pin 23 of the P34 connector which is located near the right side
of the steering column. This circuit is used to communicate and control the seat module. This circuit
"locks out" movement when the vehicle is not in park and also causes seat position recall when
used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for
fully seated and clean contacts.
To check and reset the soft stop limits in memory, use the control switches on the side of the seat
to move the seat in one direction to the end of travel, then energize the seat again in the same
direction until it stops and for three additional seconds after it stops. The amount that the seat
moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat
this procedure for each of the directions of movement (one at a time).
NOTE:
IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF
SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM
(AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE
MANUAL).
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation
Seat Heater Control Module: Description and Operation
SYSTEM OPERATION
The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate
the electric seat heater elements. Two modules are used in the vehicle, one for each front seat.
The HSCM for each seat is installed on front portion of each cushion pan. The wire harness
connector is secured by an integral clip to the inside surface of the outboard seat cushion frame.
Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat
cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery
feed, and a ground. The only HSCM output is the feed for the seat heating elements.
The HSCM cannot be repaired and, if faulty or damaged, it must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation > Page 6391
Seat Heater Control Module: Testing and Inspection
Before testing the heated seat control module, test the heated seat switch, the heated seat
elements, and the heated seat sensor as described. If testing of the heated seat switch, elements,
and sensor reveals no problems, proceed as follows.
1. Replace the heated seat control module with a known good unit and test the operation of the
heated seats. If OK, discard the faulty heated seat
control module. If not OK, go to Step 2.
2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat
sensor to the heated seat control module. Repair any
short or open circuits as required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation > Page 6392
Seat Heater Control Module: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the
vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the
module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5.
Remove module from seat cushion pan.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Technical Service Bulletins > Customer Interest for Roof Rack Frame: > 23-11-00 > Mar > 00 > Roof Panel Wavy or has Depressions
Roof Rack Frame: Customer Interest Roof Panel - Wavy or has Depressions
BULLETIN NUMBER: 23-11-00
GROUP: Body
DATE: Mar.24, 2000
SUBJECT: Roof Panel Wavy Or Has Depressions
MODELS: 1996 - 2000 (NS) Town & County/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-28-96, DATED MAY 3,
1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1996
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
OVERVIEW: This bulletin involves applying heat to the roof panel to remove depression(s). This
Repair Procedure is not intended to be used to correct any type of impact/damage caused dents.
SYMPTOM/CONDITION: The roof panel surface exhibits waviness or depression(s) near the front
of the character features or skid strip for roof rack equipped vehicles. Typically the shape of the
depression or waviness will be elliptical or along a line across the vehicle. The depression(s) will go
away on their own as the vehicle is exposed to higher ambient temperatures and sun load.
DIAGNOSIS: While standing in front of the vehicle, visually inspect the roof panel, if any
depression(s) or waviness is seen in one or both areas shown in Figure 1, perform the following
Repair Procedure only if the customer is unwilling to wait for higher ambient temperatures to
remove the depression(s).
EQUIPMENT REQUIRED. Heat Gun such as Pentastar Service Equipment (PSE) W-PH12OO
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Technical Service Bulletins > Customer Interest for Roof Rack Frame: > 23-11-00 > Mar > 00 > Roof Panel Wavy or has Depressions > Page 6402
Figure 1
1. Refer to Figure 1 and apply heat to of the areas indicated for one depression at a time. The heat
gun should be set for approximately 500° F (260° C). Keep the gun moving constantly to avoid
scorching the paint. Avoid applying heat directly to the roof rack skid strips if so equipped.
2. Continue applying heat evenly until the depression is removed, the roof panel will usually "pop"
when the depression removal is complete.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Roof Rack Frame: > 23-11-00 > Mar > 00 >
Roof Panel - Wavy or has Depressions
Roof Rack Frame: All Technical Service Bulletins Roof Panel - Wavy or has Depressions
BULLETIN NUMBER: 23-11-00
GROUP: Body
DATE: Mar.24, 2000
SUBJECT: Roof Panel Wavy Or Has Depressions
MODELS: 1996 - 2000 (NS) Town & County/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-28-96, DATED MAY 3,
1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1996
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
OVERVIEW: This bulletin involves applying heat to the roof panel to remove depression(s). This
Repair Procedure is not intended to be used to correct any type of impact/damage caused dents.
SYMPTOM/CONDITION: The roof panel surface exhibits waviness or depression(s) near the front
of the character features or skid strip for roof rack equipped vehicles. Typically the shape of the
depression or waviness will be elliptical or along a line across the vehicle. The depression(s) will go
away on their own as the vehicle is exposed to higher ambient temperatures and sun load.
DIAGNOSIS: While standing in front of the vehicle, visually inspect the roof panel, if any
depression(s) or waviness is seen in one or both areas shown in Figure 1, perform the following
Repair Procedure only if the customer is unwilling to wait for higher ambient temperatures to
remove the depression(s).
EQUIPMENT REQUIRED. Heat Gun such as Pentastar Service Equipment (PSE) W-PH12OO
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Roof Rack Frame: > 23-11-00 > Mar > 00 >
Roof Panel - Wavy or has Depressions > Page 6408
Figure 1
1. Refer to Figure 1 and apply heat to of the areas indicated for one depression at a time. The heat
gun should be set for approximately 500° F (260° C). Keep the gun moving constantly to avoid
scorching the paint. Avoid applying heat directly to the roof rack skid strips if so equipped.
2. Continue applying heat evenly until the depression is removed, the roof panel will usually "pop"
when the depression removal is complete.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time
Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time
NUMBER: 23-008-00 Rev. B
GROUP: Body
DATE: Nov. 24, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED
JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS.
SUBJECT: Child Seat Tether Anchors
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) Lebaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2001 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 JA Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
**2000 (TJ) Wrangler**
1999 - 2000 (WJ) Grand Cherokee
1989 - **2000** (XJ) Cherokee/Wagoneer
1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION
NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER
WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING
DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY
ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS.
DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in
the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the
performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit
for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat
tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit
containing all necessary parts and a detailed instruction sheet.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6414
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6415
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6416
PARTS REQUIRED:
POLICY: Customer Satisfaction
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6417
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 6418
TIME ALLOWANCE:
FAILURE CODE:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical
Service Bulletins > Memory Power Seat - Travel Range
Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range
NO: 08-44-98
GROUP: Electrical
DATE: Dec. 11, 1998
SUBJECT: Memory Power Seat Travel Range
MODELS:
1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand
Cherokee 1996-1998 (ZG) Grand Cherokee (International Market)
DISCUSSION:
The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and
remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in
MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the
motor end, fails to change. The feedback voltage potentiometers vary the position sensing
feedback voltage based on seat position/movement (no movement, no change in position sensing
feedback voltage). The seat motor automatically stops at the soft stop on any subsequent
movement so the motor does not run into a stall condition (end of travel).
The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when
something is stuck under or behind the seat that causes the seat to stop moving). These soft stops
can prevent the seat from being able to have memory positions set over the full range of travel.
Also, positions that were previously programmed to locations beyond an updated soft stop limit will
not be recalled as they are "out of range."
When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed
into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure
to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat
operation.
There are two potential reasons for intermittent memory functioning of the seats. The first
possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned
by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in
the seat's path or a person shifting their body while a power seat motor is in operation.)
The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can
be caused by a poor connection at pin 23 of the P34 connector which is located near the right side
of the steering column. This circuit is used to communicate and control the seat module. This circuit
"locks out" movement when the vehicle is not in park and also causes seat position recall when
used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for
fully seated and clean contacts.
To check and reset the soft stop limits in memory, use the control switches on the side of the seat
to move the seat in one direction to the end of travel, then energize the seat again in the same
direction until it stops and for three additional seconds after it stops. The amount that the seat
moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat
this procedure for each of the directions of movement (one at a time).
NOTE:
IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF
SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM
(AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE
MANUAL).
POLICY: Information Only
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Testing and
Inspection
Power Seat Motor: Testing and Inspection
1. Remove power seat switch. Refer to Seat Switch Replacement. 2. Disconnect wire connector. 3.
Using a voltmeter check for battery voltage at Pin 5. Using an ohmmeter, check Pin 1 for ground.
Seat Motor Test
4. To test the seat motors, verify proper seat responses. Using two jumper wires, connect one to a
battery supply and the other to a ground. Connect
the other ends to the seat wire harness connector as described. If any motor fails to operate, check
wire connectors to the motor. If not OK, repair as necessary If OK, replace power seat adjuster.
Refer to Power Seat Adjuster Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Testing and
Inspection > Page 6426
Power Seat Motor: Service and Repair
The Power Seat Adjuster and motors are serviced as an assembly.
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove seat from vehicle. 3. Remove seat
cushion pan. 4. Remove nut holding recliner to seat back frame. 5. Remove bolts holding seat back
frame to seat track. 6. Remove stud on seat back frame from recliner. 7. Remove seat back from
recliner.
INSTALLATION
Transfer the power recliner, wire harness and trim covers to replacement power seat adjuster. 1.
For installation, reverse the above procedures. 2. Reinstall seat in vehicle. Tighten fasteners to 60
Nm (44 ft. lbs.) torque.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection
Power Seat Switch: Testing and Inspection
1. Remove seat switch from seat. Refer to Seat Switch Replacement.
Seat Switch Test
2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the
switch positions, replace switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Page 6430
Power Seat Switch: Service and Repair
REMOVAL AND INSTALLATION
Negative Battery Cable
1. Disconnect and isolate the battery negative cable.
Bucket See Cushion Side Cover Remove/Install
2. Remove seat cushion side cover.
Set Switch Wire Connector
3. Disconnect the wire connector to the seat switch and remove side cover from vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Testing and Inspection
Seat Cushion: Testing and Inspection
1. Disconnect and isolate the battery negative cable. Unplug the 4-way heated seat cushion wire
harness connector. 2. Check for continuity between the two heated seat driver circuit cavities of the
seat cushion cover half of the heated seat cushion wire harness
connector. There should be continuity If OK, go to Step 3. If not OK, replace the faulty seat cushion
cover.
3. Check for continuity between one of the heated seat driver circuit cavities of the seat cushion
cover half of the heated seat cushion wire harness
connector and the seat cushion frame. There should be no continuity. If OK, go to the Seat Back
test. If not OK, replace the faulty seat cushion cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions
Seat Heater: Technical Service Bulletins Electrical - Seat Heater Harness/BCM Pin-Out Revisions
NUMBER: 26-04-99
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1999 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-9105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 6438
8N-4
Revision to the Body Control Module connector pin-out
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Electrical - Seat Heater Harness/BCM Pin-Out Revisions > Page 6439
8W-80-13
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Page 6440
Seat Heater: Description and Operation
The content of this article reflects the changes called out by TSB 26-04-99.
INTRODUCTION
Individually controlled electrically heated front seats are available factory-installed optional
equipment. The seat heaters will only operate when the ignition switch is in the On position, and
the surface temperature at the front seat heating element sensors is below the designed
temperature set points of the system. The heated seat system will not operate in ambient
temperatures greater than about 32 °C (90 °F).
There are separate three-position switches for each front seat located in the inboard seat cushion
side shield. An Off, Low, or High position can be selected with each switch, and Light-Emitting
Diodes (LED) for each switch illuminate to give a visual indication that the system is turned on. The
Low heat position set point is about 32 °C (90 °F), and the High heat position set point is about 38
°C (100 °F). Each switch controls a Heated Seat Control Module (HSCM) mounted to the seat
cushion frame under each front seat.
When a seat heater is turned on, a sensor located near the seat cushion electric heater element
provides the HSCM with an input indicating the surface temperature of the seat cushion. If the
surface temperature input is below the temperature set point for the selected Low or High switch
position, a relay within the HSCM energizes the heating elements in the seat cushion and back.
When the sensor input indicates the correct temperature set point has been achieved, the HSCM
de-energizes the relay The HSCM will continue to cycle the relay as needed to maintain the
temperature set point.
The HSCM will automatically turn off the heating elements if it detects an open in the sensor circuit,
or a short in the heating element circuit causing an excessive current draw. The system is also
turned off automatically when the ignition switch is turned to the Off position. The control circuit
operates on ignition switched battery feed through a fuse in the junction block. The heating
elements operate on battery feed supplied through the power seat circuit breaker located in the
wire harness under the driver's seat.
SYSTEM OPERATION
Heated Seat Element And Sensor Two heated seat heating elements are used in each front seat,
one for the seat cushion and the other for the seat back. The two element for each seat are
connected in series with the HSCM.
The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature
sensor is used for each seat, and it is integrated into the seat cushion heating element.
The heating elements are sewn into the seat cushion cover and seat back cover assemblies, which
are serviced individually. The heating elements and temperature sensor cannot be repaired and, if
faulty or damaged, the affected seat cover assembly must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection >
Heated Seat System
Seat Heater: Testing and Inspection Heated Seat System
Before testing the individual components in the heated seat system, check the following:
- If the heated seat switch LED doesn't light with the ignition switch in the On position and the
heated seat switch in the Low or High position, check the fuse in the junction block. If the Fuse is
OK, test the heated seat switch as described. If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.
- If the heated seat switch LED lights, but the heating elements don't heat, check the circuit breaker
in the junction block. If the circuit breaker is OK, test the heated seat elements as described. If not
OK, replace the faulty circuit breaker.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection >
Heated Seat System > Page 6443
Seat Heater: Testing and Inspection Heated Seat Element
The wire harness connectors for the seat cushion and seat back heating elements are located
under the seat, near the rear edge of the seat cushion frame.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Description and Operation
Seat Heater Control Module: Description and Operation
SYSTEM OPERATION
The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate
the electric seat heater elements. Two modules are used in the vehicle, one for each front seat.
The HSCM for each seat is installed on front portion of each cushion pan. The wire harness
connector is secured by an integral clip to the inside surface of the outboard seat cushion frame.
Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat
cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery
feed, and a ground. The only HSCM output is the feed for the seat heating elements.
The HSCM cannot be repaired and, if faulty or damaged, it must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Description and Operation > Page 6447
Seat Heater Control Module: Testing and Inspection
Before testing the heated seat control module, test the heated seat switch, the heated seat
elements, and the heated seat sensor as described. If testing of the heated seat switch, elements,
and sensor reveals no problems, proceed as follows.
1. Replace the heated seat control module with a known good unit and test the operation of the
heated seats. If OK, discard the faulty heated seat
control module. If not OK, go to Step 2.
2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat
sensor to the heated seat control module. Repair any
short or open circuits as required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Description and Operation > Page 6448
Seat Heater Control Module: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the
vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the
module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5.
Remove module from seat cushion pan.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and
Operation
Seat Heater Switch: Description and Operation
SYSTEM OPERATION
The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The
two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective
Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both
the driver and the front seat passenger can select a preferred seat heating mode.
Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat
that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If
either switch or LED is faulty, the switch must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and
Operation > Page 6452
Seat Heater Switch: Testing and Inspection
1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion
side cover. Check for continuity between the ground circuit cavity of the switch wire harness
connector
and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit
as required.
3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery
voltage at the fused ignition switch output circuit
cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position,
disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open
circuit as required.
4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK,
replace the faulty switch.
5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty
switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and
Operation > Page 6453
Seat Heater Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755),
gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect
wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out
switch from rear of switch bezel. 5. Remove switch from bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Description
and Operation
Seat Heater Thermostat: Description and Operation
SYSTEM OPERATION
Heated Seat Element And Sensor Two heated seat heating elements are used in each front seat,
one for the seat cushion and the other for the seat back. The two element for each seat are
connected in series with the HSCM.
The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature
sensor is used for each seat, and it is integrated into the seat cushion heating element.
The heating elements are sewn into the seat cushion cover and seat back cover assemblies, which
are serviced individually. The heating elements and temperature sensor cannot be repaired and, if
faulty or damaged, the affected seat cover assembly must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Description
and Operation > Page 6457
Seat Heater Thermostat: Testing and Inspection
The wire harness connector for the seat cushion heating element and sensor are located under the
seat, near the rear edge of the seat cushion frame.
1. Disconnect and isolate the battery negative cable. Unplug the 4-way heated seat cushion wire
harness connector. 2. Using an ohmmeter, check the resistance between the heated seat switch
output circuit cavity and the ground circuit cavity of the seat cushion
cover half of the heated seat cushion wire harness connector. The sensor resistance should be
between 2 kilo ohms and 200 kilo ohms. If OK, test the heated seat control module as described. If
not OK, replace the faulty seat cushion cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> Customer Interest for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles
Seat Latch: Customer Interest Quad Seat Easy Entry Latch - Rattles
NUMBER: 23-27-99
GROUP: Body
DATE: Jul. 23, 1999
SUBJECT: Quad Seat Easy Entry Latch Rattle
OVERVIEW: This bulletin involves installing flock tape and grease to the quad seat latch.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: Rattle noise is heard when driving
DIAGNOSIS: Release the easy entry latch and tilt the quad seats forward. Inspect the easy entry
latch striker for damaged mylar tape. If the tape is damaged, perform the Repair Procedure.
PARTS REQUIRED:
1 04773968 Tape, Flock
1 04318063 Grease
REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE
SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE
FACILITY SPECIAL EQUIPMENT.
1. Remove the mylar tape from the easy entry latch striker (Fig. 1)
2. Clean the inside surface of the easy entry latch hook and the easy entry latch striker with
isopropyl alcohol.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> Customer Interest for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles > Page 6466
3. Apply flocked tape, p/n 04773968, to the inside surface of the easy entry latch hook (Fig 2).
4. Apply a thin coat of grease, p/n 04318063, to the easy entry latch striker.
5. Return the quad seat to its latched/normal position.
6. Repeat for the other quad seat.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-41-64-93 Apply Tape and Grease to Both Seats 0.2 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles
Seat Latch: All Technical Service Bulletins Quad Seat Easy Entry Latch - Rattles
NUMBER: 23-27-99
GROUP: Body
DATE: Jul. 23, 1999
SUBJECT: Quad Seat Easy Entry Latch Rattle
OVERVIEW: This bulletin involves installing flock tape and grease to the quad seat latch.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: Rattle noise is heard when driving
DIAGNOSIS: Release the easy entry latch and tilt the quad seats forward. Inspect the easy entry
latch striker for damaged mylar tape. If the tape is damaged, perform the Repair Procedure.
PARTS REQUIRED:
1 04773968 Tape, Flock
1 04318063 Grease
REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE
SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE
FACILITY SPECIAL EQUIPMENT.
1. Remove the mylar tape from the easy entry latch striker (Fig. 1)
2. Clean the inside surface of the easy entry latch hook and the easy entry latch striker with
isopropyl alcohol.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles > Page 6472
3. Apply flocked tape, p/n 04773968, to the inside surface of the easy entry latch hook (Fig 2).
4. Apply a thin coat of grease, p/n 04318063, to the easy entry latch striker.
5. Return the quad seat to its latched/normal position.
6. Repeat for the other quad seat.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-41-64-93 Apply Tape and Grease to Both Seats 0.2 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood
Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood.
Negative Battery Cable
2. Disconnect and isolate the battery negative cable. 3. Using a small flat blade screws driver, pry
trigger switch from top of the radiator closure panel. 4. Disconnect the trigger switch from the wire
connector and remove the switch.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams
Power Door Lock Switch: Diagrams
Driver Door Lock Switch
Passenger Door Lock Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 6481
Power Door Lock Switch: Testing and Inspection
1. Remove door lock/power window switch bezel assembly from door. Refer to Power Door Lock
Switch Replacement. 2. Disconnect wire connector from back of door lock switch. 3. Depress
switch to LOCK position.
Door Lock Switch
Door Lock Switch Test
4. Using an ohmmeter, test switch resistance between Pins 2 and 3. Refer to Door Lock Switch
Test. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. If
resistance values are not within the parameters shown replace the door lock switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 6482
Power Door Lock Switch: Service and Repair
The Power Door Lock Switch is the only serviceable part on the power door lock / window switch
bezel.The window switches, window lock - out, and power vent window switch is serviced with the
bezel.
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the negative battery cable. 2. Open left door, remove screw cover near
inside door release handle. 3. Remove two screws to door lock / window switch bezel. One under
the screw cover removed in previous step and one to the rear of the front door
vent opening.
4. Pull out and up on bezel to release from door trim panel. 5. Disconnect door lock switch
connector. 6. Remove two door lock switch retaining screws and remove switch from vehicle.
INSTALLATION
1. For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Testing and Inspection
Power Mirror Switch: Testing and Inspection
1. Remove power mirror switch. Refer to Instrument Panel and Systems for Replacement
Procedures. 2. Disconnect wiring harness at switch connector.
Mirror Switch Test
3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in
the table are not obtained, replace the switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Service and Repair > Power Mirror Switch
Power Mirror Switch: Service and Repair Power Mirror Switch
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to
Instrument Cluster Bezel Replacement.
Power Mirror Switch
3. Disconnect wire connector from back of power mirror switch. 4. Disengage lock tabs above and
below the mirror switch. 5. Pull power mirror switch from headlamp switch bezel. The power mirror
switch bezel is mounted to the bottom of the instrument cluster bezel. 6. Remove power mirror
switch.
INSTALLATION
For installation, reverse the above procedures.
REMOVAL AND INSTALLATION
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Service and Repair > Power Mirror Switch > Page 6488
Power Mirror/Window Switch
Refer to Instrument Panel and Systems for service procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Service and Repair > Power Mirror Switch > Page 6489
Power Mirror Switch: Service and Repair Power Mirror Switch Lamp
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. Refer to
Instrument Cluster Bezel Replacement. 3. Remove instrument cluster bezel.
Power Mirror Switch Lamp
4. Rotate bulb socket counterclockwise one quarter turn. 5. Pull bulb socket from back of power
mirror switch.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection
Power Seat Switch: Testing and Inspection
1. Remove seat switch from seat. Refer to Seat Switch Replacement.
Seat Switch Test
2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the
switch positions, replace switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Page 6493
Power Seat Switch: Service and Repair
REMOVAL AND INSTALLATION
Negative Battery Cable
1. Disconnect and isolate the battery negative cable.
Bucket See Cushion Side Cover Remove/Install
2. Remove seat cushion side cover.
Set Switch Wire Connector
3. Disconnect the wire connector to the seat switch and remove side cover from vehicle.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation
Seat Heater Switch: Description and Operation
SYSTEM OPERATION
The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The
two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective
Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both
the driver and the front seat passenger can select a preferred seat heating mode.
Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat
that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If
either switch or LED is faulty, the switch must be replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation > Page 6497
Seat Heater Switch: Testing and Inspection
1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion
side cover. Check for continuity between the ground circuit cavity of the switch wire harness
connector
and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit
as required.
3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery
voltage at the fused ignition switch output circuit
cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position,
disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open
circuit as required.
4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK,
replace the faulty switch.
5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty
switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation > Page 6498
Seat Heater Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755),
gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect
wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out
switch from rear of switch bezel. 5. Remove switch from bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams
Liftgate Ajar Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion
Strut / Shock Tower: Customer Interest Suspension/Body - Strut Tower Corrosion
NUMBER: 23-044-02
GROUP: Body
DATE: Oct. 14, 2002
SUBJECT: NS Strut Tower Corrosion
OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan
SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between
the strut and upper load path beam inner panel (inner fender).
DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of
the following repair procedures.
NOTE:
ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD
BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED
EQUIPMENT REQUIRED
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or
primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE:
REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE
PARTS KITS.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion >
Page 6510
TIME ALLOWANCE
FAILURE CODE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower
Corrosion
Strut / Shock Tower: All Technical Service Bulletins Suspension/Body - Strut Tower Corrosion
NUMBER: 23-044-02
GROUP: Body
DATE: Oct. 14, 2002
SUBJECT: NS Strut Tower Corrosion
OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan
SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between
the strut and upper load path beam inner panel (inner fender).
DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of
the following repair procedures.
NOTE:
ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD
BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED
EQUIPMENT REQUIRED
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or
primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE:
REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE
PARTS KITS.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower
Corrosion > Page 6516
TIME ALLOWANCE
FAILURE CODE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins >
Customer Interest for Weatherstrip: > 23-34-98 > Aug > 98 > Door Weatherstrip - Falls Off Mounting Flange
Weatherstrip: Customer Interest Door Weatherstrip - Falls Off Mounting Flange
NO: 23-34-98
GROUP: Body
DATE: Aug. 7, 1998
SUBJECT: Front Door Body Mounted Weatherstrip Retention
MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION:
The front door body mounted weatherstrip falls off mounting flange, usually along the top of the
door opening.
DIAGNOSIS:
Open the door and visually inspect the weatherstrip on the body. If it is off the mounting flange or
pulls off easily, perform the Repair Procedure.
NOTE:
THIS REPAIR PROCEDURE IS ALSO REQUIRED IF THE BODY MOUNTED WEATHERSTRIP
IS REMOVED FOR ANY REASON.
PARTS REQUIRED:
AR NPN Isopropyl Alcohol
REPAIR PROCEDURE:
This bulletin involves removing the slip coating on the weatherstrip and mounting flange.
1. Remove the top half of the body mounted weatherstrip from the mounting flange starting at the
upper B-pillar corner down to the beltline at the A-pillar and B-pillar. Leave the bottom half of the
weatherstrip installed.
2. Apply alcohol to a clean rag or paper towel and wipe both sides of the sheet metal flange the
seal mounts to.
3. Use a clean portion of the rag with alcohol on it and wipe the weatherstrip throat/groove/slot that
mounts over the sheet metal flange. Try to get the rag as deep into the throat of the seal as
possible without bending it open. If done properly, there will be some black residue on the rag from
the weatherstrip.
4. If the throat of the weatherstrip becomes opened up, squeeze it back with hand pressure.
5. Reinstall the weatherstrip on the flange, make sure it is fully seated.
6. Repeat steps 1 through 5 for the other side.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-51-09-92 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 23-34-98 > Aug > 98 > Door Weatherstrip - Falls Off Mounting Flange
Weatherstrip: All Technical Service Bulletins Door Weatherstrip - Falls Off Mounting Flange
NO: 23-34-98
GROUP: Body
DATE: Aug. 7, 1998
SUBJECT: Front Door Body Mounted Weatherstrip Retention
MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION:
The front door body mounted weatherstrip falls off mounting flange, usually along the top of the
door opening.
DIAGNOSIS:
Open the door and visually inspect the weatherstrip on the body. If it is off the mounting flange or
pulls off easily, perform the Repair Procedure.
NOTE:
THIS REPAIR PROCEDURE IS ALSO REQUIRED IF THE BODY MOUNTED WEATHERSTRIP
IS REMOVED FOR ANY REASON.
PARTS REQUIRED:
AR NPN Isopropyl Alcohol
REPAIR PROCEDURE:
This bulletin involves removing the slip coating on the weatherstrip and mounting flange.
1. Remove the top half of the body mounted weatherstrip from the mounting flange starting at the
upper B-pillar corner down to the beltline at the A-pillar and B-pillar. Leave the bottom half of the
weatherstrip installed.
2. Apply alcohol to a clean rag or paper towel and wipe both sides of the sheet metal flange the
seal mounts to.
3. Use a clean portion of the rag with alcohol on it and wipe the weatherstrip throat/groove/slot that
mounts over the sheet metal flange. Try to get the rag as deep into the throat of the seal as
possible without bending it open. If done properly, there will be some black residue on the rag from
the weatherstrip.
4. If the throat of the weatherstrip becomes opened up, squeeze it back with hand pressure.
5. Reinstall the weatherstrip on the flange, make sure it is fully seated.
6. Repeat steps 1 through 5 for the other side.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-51-09-92 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6534
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6535
Cruise Control Servo: Description and Operation
DESCRIPTION
The servo unit consists of a solenoid valve body, and a vacuum chamber.
OPERATION
The PCM controls the solenoid valve body. The solenoid valve body controls the application and
release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is
serviced only as a complete assembly.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6536
Cruise Control Servo: Testing and Inspection
1. Turn ignition switch to the ON position without starting engine. Activate speed control ON switch.
Fig. 4 Servo Harness Connector
2. Disconnect the four-way electrical connector and the vacuum harness at the servo. 3. Connect a
jumper wire from Pin 3 of the servo to Pin 3 of the wire connector. 4. Ground Pins 2 and 4 in the
servo. Do not connect pin 1. 5. Connect a hand held vacuum pump to the vacuum nipple and apply
10 - 15 inches of vacuum. 6. If servo pulls cable, replace servo. 7. Ground Pin 1 on servo. 8. Check
that the throttle cable pulls in and holds as long as the vacuum pump is connected. After one
minute, check if cable is still holding. If cable
does not hold replace the servo.
9. Disconnect jumper from pin 3. Cable should return to rest position. If not, replace servo.
10. Connect 4 way electrical connector and vacuum harness to servo.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6537
Cruise Control Servo: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. Remove air cleaner resonator.
Fig. 11 Speed Control Cable End
3. Disconnect the throttle and speed control cable ends from throttle body.
Speed Control Cable Case And Vacuum Line - Typical
4. Depress lock tabs holding speed control cable casing to cable mount bracket. 5. Disconnect
vacuum line from nipple on air intake plenum. 6. Remove tie wrap holding vacuum line, throttle
cable, and speed control cable together.
Speed Control Servo
7. Remove bolt holding speed control servo to side of battery tray/vacuum reservoir.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6538
8. Remove speed control servo from battery tray. 9. Disconnect wire connector from speed control
servo.
10. Disconnect vacuum line from speed control servo that leads to the battery tray/vacuum
reservoir. 11. Remove speed control servo.
INSTALLATION
Transfer speed control cable to replacement speed control servo. Reverse the preceding operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and
Operation
Cruise Control Servo Cable: Description and Operation
DESCRIPTION
The speed control servo cable is connected between the speed control vacuum servo diaphragm
and the throttle body control linkage.
OPERATION
This cable causes the throttle control linkage to open or close the throttle valve in response to
movement of the vacuum servo diaphragm.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and
Operation > Page 6542
Cruise Control Servo Cable: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. Remove air cleaner resonator.
Fig. 11 Speed Control Cable End
3. Disconnect throttle and speed control cable ends from throttle body.
Speed Control Cable
4. Depress lock tabs holding speed control cable casing to cable mount bracket. 5. Remove tie
wrap holding vacuum line, throttle cable, and speed control cable together. 6. Remove nuts holding
speed control cable case to servo. 7. Remove cable case from servo. 8. Remove hairpin clip
holding cable end to servo diaphragm.
INSTALLATION
Reverse the preceding operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations
Speed Control Switches
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6546
Cruise Control Switch: Description and Operation
DESCRIPTION
There are two separate switch pods that operate the speed control system.
OPERATION
The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON,
OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual
for more information on speed control switch functions and setting procedures.
The individual switches cannot be repaired. If one switch fails, the entire switch module must be
replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6547
Cruise Control Switch: Testing and Inspection
Refer to the appropriate Powertrain Diagnostics for switch test values.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 6548
Cruise Control Switch: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove
airbag/horn pad from steering wheel, refer to Airbags and Seat Belts/Airbags for proper
procedures. 4. Disconnect wire connector from horn switch, airbag, and speed control switches.
Speed Control Switches
5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control
switch from airbag/horn pad.
INSTALLATION
Reverse the preceding operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > Customer Interest for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does
Not Maintain Speed on Grades
Cruise Control Vacuum Reservoir: Customer Interest Speed Control - Does Not Maintain Speed on
Grades
NUMBER: 08-27-99
GROUP: Electrical
EFFECTIVE DATE: Aug. 27, 1999
SUBJECT: Speed Control Does Not Maintain Set Speed While Climbing a Grade
OVERVIEW: This bulletin involves replacing the battery tray/vacuum reservoir assembly because
of speed control vacuum loss while on up hill grade.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO SEPT. 1, 1999 AND EQUIPPED
WITH SPEED CONTROL, SALES CODE NHM) AND A GASOLINE ENGINE.
SYMPTOM/CONDITION: Vehicle loses more than 5 mph (8 kph) while climbing a grade with the
speed control engaged because of a leaking check valve in the battery tray/vacuum reservoir
assembly. The check valve traps vacuum in the reservoir to allow the speed control to work under
low manifold vacuum conditions. The valve may become contaminated and cause it not to seal
intermittently. This can cause a loss of vacuum to the servo while driving on a long up hill grade.
DIAGNOSIS: Verify the ignition switch and all accessories are turned off. Disconnect the negative
and positive battery cables. Remove the battery hold down (Figure 1). Remove the battery from the
vehicle. Disconnect the vacuum line at the vacuum reservoir on the battery tray that goes to the
speed control servo. Connect a hand held vacuum pump to the small/top nipple on the vacuum
reservoir and apply 20 in. of vacuum. If the vacuum leaks down more than 2 in. in five minutes
perform the Repair Procedure, if not look for other sources of vacuum leaks. If no other source of
vacuum leak is found, perform the Repair Procedure.
PARTS REQUIRED:
1 04716740AB Tray, Battery/Vacuum Reservoir
EQUIPMENT REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > Customer Interest for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does
Not Maintain Speed on Grades > Page 6557
Hand Vacuum Pump
REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE
SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE
FACILITY SPECIAL EQUIPMENT.
1. Remove the nut and two bolts from the battery tray, Figure 1.
2. Remove the speed control servo attaching bolt from the battery tray.
3. Disconnect the vacuum lines from the battery tray vacuum reservoir.
4. Remove the battery tray from the vehicle and discard.
5. Connect the vacuum lines to the revised battery tray vacuum reservoir, p/n 04716740AB.
6. Attach the speed control servo to the battery tray. Tighten the bolt to 6 Nm. (50 in. lbs.).
7. Install the battery tray, tighten the nut and two bolts to 16 Nm. (140 in. lbs.).
8. Install the battery; tighten the hold down clamp bolt to 20 Nm (180 in. lbs.)
9. Connect the positive and negative battery terminals.
10. Set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-08-05-90 0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed
Control - Does Not Maintain Speed on Grades
Cruise Control Vacuum Reservoir: All Technical Service Bulletins Speed Control - Does Not
Maintain Speed on Grades
NUMBER: 08-27-99
GROUP: Electrical
EFFECTIVE DATE: Aug. 27, 1999
SUBJECT: Speed Control Does Not Maintain Set Speed While Climbing a Grade
OVERVIEW: This bulletin involves replacing the battery tray/vacuum reservoir assembly because
of speed control vacuum loss while on up hill grade.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO SEPT. 1, 1999 AND EQUIPPED
WITH SPEED CONTROL, SALES CODE NHM) AND A GASOLINE ENGINE.
SYMPTOM/CONDITION: Vehicle loses more than 5 mph (8 kph) while climbing a grade with the
speed control engaged because of a leaking check valve in the battery tray/vacuum reservoir
assembly. The check valve traps vacuum in the reservoir to allow the speed control to work under
low manifold vacuum conditions. The valve may become contaminated and cause it not to seal
intermittently. This can cause a loss of vacuum to the servo while driving on a long up hill grade.
DIAGNOSIS: Verify the ignition switch and all accessories are turned off. Disconnect the negative
and positive battery cables. Remove the battery hold down (Figure 1). Remove the battery from the
vehicle. Disconnect the vacuum line at the vacuum reservoir on the battery tray that goes to the
speed control servo. Connect a hand held vacuum pump to the small/top nipple on the vacuum
reservoir and apply 20 in. of vacuum. If the vacuum leaks down more than 2 in. in five minutes
perform the Repair Procedure, if not look for other sources of vacuum leaks. If no other source of
vacuum leak is found, perform the Repair Procedure.
PARTS REQUIRED:
1 04716740AB Tray, Battery/Vacuum Reservoir
EQUIPMENT REQUIRED:
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed
Control - Does Not Maintain Speed on Grades > Page 6563
Hand Vacuum Pump
REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE
SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE
FACILITY SPECIAL EQUIPMENT.
1. Remove the nut and two bolts from the battery tray, Figure 1.
2. Remove the speed control servo attaching bolt from the battery tray.
3. Disconnect the vacuum lines from the battery tray vacuum reservoir.
4. Remove the battery tray from the vehicle and discard.
5. Connect the vacuum lines to the revised battery tray vacuum reservoir, p/n 04716740AB.
6. Attach the speed control servo to the battery tray. Tighten the bolt to 6 Nm. (50 in. lbs.).
7. Install the battery tray, tighten the nut and two bolts to 16 Nm. (140 in. lbs.).
8. Install the battery; tighten the hold down clamp bolt to 20 Nm (180 in. lbs.)
9. Connect the positive and negative battery terminals.
10. Set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-08-05-90 0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > Page 6564
Cruise Control Vacuum Reservoir: Description and Operation
OPERATION
The reservoir contains a one-way check valve to trap engine vacuum in the reservoir. When engine
vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to
maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be
replaced if faulty.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > Page 6565
Cruise Control Vacuum Reservoir: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove battery, Refer to Battery Replacement. 3.
Remove battery tray. 4. Disconnect vacuum hoses from vacuum reservoir
INSTALLATION
1. Connect vacuum hoses to vacuum reservoir. 2. Install battery tray 3. Install battery, Refer to
Battery Replacement. 4. Connect negative cable to battery.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Solenoid > Component Information > Description and
Operation
Cruise Control Vacuum Solenoid: Description and Operation
SPEED CONTROL SOLENOIDS-PCM OUTPUT
The speed control vacuum and vent solenoids are operated by the PCM. When the PCM supplies
a ground to the vacuum and vent solenoids, the speed control system opens the throttle plate.
When the PCM removes the ground from the vacuum and vent solenoids, the throttle blade closes.
The PCM balances the two solenoids to maintain the set speed.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations
Speed Control Switches
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations > Page 6573
Cruise Control Switch: Description and Operation
DESCRIPTION
There are two separate switch pods that operate the speed control system.
OPERATION
The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON,
OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner's manual
for more information on speed control switch functions and setting procedures.
The individual switches cannot be repaired. If one switch fails, the entire switch module must be
replaced.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations > Page 6574
Cruise Control Switch: Testing and Inspection
Refer to the appropriate Powertrain Diagnostics for switch test values.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations > Page 6575
Cruise Control Switch: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove
airbag/horn pad from steering wheel, refer to Airbags and Seat Belts/Airbags for proper
procedures. 4. Disconnect wire connector from horn switch, airbag, and speed control switches.
Speed Control Switches
5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control
switch from airbag/horn pad.
INSTALLATION
Reverse the preceding operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent
Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page
6584
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page
6590
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Page 6591
Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation
OPERATION
The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM.
The PCM determines acceleration rates. The speed control software in the PCM uses vehicle
speed and acceleration to control to the set speed.
Vehicles with a 3 speed automatic or manual transmission have a Vehicle Speed Sensor (VSS)
mounted to an adapter near the transmission output shaft. The sensor is driven through the
adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to
determine vehicle speed and to maintain speed control set speed. Refer to the appropriate
Powertrain Diagnostic Procedures for diagnosis and testing of this component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Page 6592
Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection
For diagnosis and testing of the Vehicle Speed Signal (VSS), refer to the appropriate Powertrain
Diagnostic Procedures. Also refer to the DRB scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr
> 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent
Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr
> 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 6601
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 6607
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > Page 6608
Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation
OPERATION
The 4 speed automatic Transmission Control Module (TCM) supplies the speed input to the PCM.
The PCM determines acceleration rates. The speed control software in the PCM uses vehicle
speed and acceleration to control to the set speed.
Vehicles with a 3 speed automatic or manual transmission have a Vehicle Speed Sensor (VSS)
mounted to an adapter near the transmission output shaft. The sensor is driven through the
adapter by a speedometer pinion gear. The VSS pulse signal is monitored by the PCM to
determine vehicle speed and to maintain speed control set speed. Refer to the appropriate
Powertrain Diagnostic Procedures for diagnosis and testing of this component.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > Page 6609
Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection
For diagnosis and testing of the Vehicle Speed Signal (VSS), refer to the appropriate Powertrain
Diagnostic Procedures. Also refer to the DRB scan tool.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Description and Operation
ABS Light: Description and Operation
The amber ABS warning lamp is located on the right side of the message center located at the top
of the instrument panel.
When the ignition key is turned to the ON position, the amber ABS warning lamp is lit until the CAB
completes its self-tests and turns off the lamp (approximately 4 seconds). The amber ABS warning
lamp will illuminate when the CAB detects a condition that results in the shutdown of ABS function,
or when the body controller does not receive a CCD message from the CAB. The CAB turns on the
amber ABS warning lamp by grounding the circuit.
Under most conditions, when the amber ABS warning lamp is on, only the ABS function of the
brake system is affected; the base brake system and the ability to stop the vehicle are not affected.
The amber ABS warning lamp is controlled by the CAB and the body controller through a diode
located in the junction block. The CAB and body controller control the amber ABS warning lamp by
directly grounding the circuit.
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
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Audible Warning Device: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 6626
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 6627
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Audible Warning Device: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Chime System
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Audible Warning Device: Description and Operation
CHIME SYSTEM
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened, The announcement chime will sound one time whenever
the generator lamp, low fuel, low washer fluid, door ajar, airbag, or liftgate ajar lamps are first
illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed
is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster
warning lamp diagnostics.
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Description and Operation
Brake Warning Indicator: Description and Operation
The red BRAKE warning lamp is located in the instrument panel cluster and is used to indicate a
low brake fluid condition or that the parking brake is applied. In addition, the brake warning lamp is
turned on as a bulb check by the ignition switch every time the ignition switch is turned to the crank
position.
The warning lamp bulb is supplied a 12-volt ignition feed anytime the ignition switch is on. The bulb
is then illuminated by completing the ground circuit either through the parking brake switch, the
fluid level sensor in the master cylinder reservoir, or the ignition switch when it is turned to the
crank position.
The Brake Fluid Level switch is located in the brake fluid reservoir of the master cylinder assembly.
The purpose of the switch is to provide the driver with an early warning that brake fluid level in the
master cylinder fluid reservoir has dropped to below normal. This may indicate: Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the
hydraulic system.
- Brake shoe linings which have worn to a point requiring replacement.
As the brake fluid drops below the minimum level, the brake fluid level switch closes to ground the
brake warning light circuit. This will turn on the red BRAKE warning Light. At this time, the master
cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. If brake
fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake
hydraulic system should be checked for evidence of a leak.
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Cigarette Lighter
Relay > Component Information > Locations
Cigarette Lighter Relay: Locations
Battery Negative Cable
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Relay > Component Information > Locations > Page 6645
Power Distribution Center -- Sheet 8w-10-2
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Relay > Component Information > Locations > Page 6646
Cigarette Lighter Relay: Diagrams
Power Distribution Center
Cigar Lighter/Accessory Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Locations
Compass/Mini-Trip Computer
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Diagrams > Diagram Information and Instructions
Compass: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Diagrams > Diagram Information and Instructions > Page 6653
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Compass: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Compass/Mini-Trip Computer
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Compass/Mini-Trip Computer
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Compass: Description and Operation
COMPASS/MINI-TRIP COMPUTER
The Compass/Mini-Trip Computer is located in the overhead console. The CMTC consists of a
electronic control module with a vacuum fluorescent display (VFD) and function switches. It
displays to the driver the direction the vehicle is traveling and the current outside temperature, as
well as the following traveler navigational information: Average Fuel Economy (AVG ECO)
- Distance To Empty (DTE)
- Instantaneous Fuel Economy (ECO)
- Elapsed Time (ET)
- Trip Odometer (ODO)
Compass Mini-Trip Computer (CMTC) Switches and Display
The CMTC module in the overhead console has three buttons used to select various functions. The
CMTC selector buttons will not operate until the ignition is in the RUN position.
When the ignition switch is first turned to the RUN position, the CMTC display: Blanks momentarily
- All segments of the VFD will light for one second
- Blanks momentarily
- Returns to the last mode setting selected before the ignition was last switched OFF.
The information needed for the traveler functions is received over the CCD bus from the Body
Control Module.
If the Compass/Mini-Trip Computer has been replaced, it may be necessary to reset the calibration.
SYSTEM OPERATION
Setting The Compass
The Compass/Mini-Trip Computer module is self-calibrated and requires no adjustment. The word
CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off
after the vehicle has gone in three complete circles without stopping, in an area free of magnetic
disturbance.
If the module displays the temperature while the compass is blank or shows a false reading, the
vehicle must be demagnetized. See the service procedure.
If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module
must be replaced.
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Compass Magnetic Variance Zones
Setting The Variance
Variance is the difference between magnetic north and geographic north. To determine the
variance for the area you are in, refer to the following zone map provided. The number shown for
your area is the variance number for your area. 1. Set the Compass/Mini-Trip Computer (CMTC) to
Compass/Temperature mode. 2. Press and hold down the RESET button for 5 seconds. NOTE: If
the button is held for 10 seconds instead of 5, the CMTC will set the
variance to 8 and enter the fast calibration mode.
3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP
button to set the zone number. 5. Press the US/M button and resume normal operation,
NOTE: DO NOT ATTACH ANY MAGNETIC DEVICE SUCH AS A MAGNETIC CB ANTENNA TO
THE VEHICLE. THIS CAN CAUSE THE COMPASS TO GIVE FALSE READINGS.
Compass Mini-Trip Computer Self Diagnostic Test
The Compass Mini-Trip Computer (CMTC) is capable of performing a diagnostic self check on
many of its internal functions. CMTC diagnostics may be performed using a DRB lll scan tool and
the proper Body Diagnostic Procedures or by the following procedure. 1. With the ignition switch in
the OFF position, press both the US/M and STEP button. 2. Turn ignition switch to the ON position.
The CMTC will perform internal checks while lighting all segments of the vacuum florescent
display. Upon completion of the internal check, the CMTC will display. PASS
- FAIL
- CCD
If any segment of the CMTC fails to light replace the module.
If FAIL is displayed, replace the module.
If CCD is displayed, check the CCD and Body Control Module (BCM) for proper operation, refer to
the appropriate diagnostic test procedures. If the CCD and the BCM are OK, replace the CMTC
module.
For additional diagnostic information on the CMTC and for identifying CMTC problems, refer to the
proper Body Diagnostic Procedures.
Compass
The CMTC is self calibrating and usually requires no adjustment. The compass will continuously
perform a slow calibration to compensate for small magnetic variations common to any automobile.
Uncommon magnetic shifts may be caused by items such as magnetic base antennas, which can
permanently alter the magnetic field of the vehicle roof panel. If excessive magnetic field continues
for 5 minutes, the compass heading will go blank and only the CAL symbol will illuminate. When
this occurs, the vehicle roof panel may require demagnetizing. Refer to the demagnetizing
procedure.
Moderate magnetic shifts may, on very rare occasions, cause the compass heading to display only
one or two of the eight possible headings. Although the compass will eventually compensate for
this shift, it could take several ignition cycles. The compensation process can be expedited by
manually activating the fast calibration routine. Refer to the fast calibrating procedure. This
procedure may be performed anytime that the compass appears to be inaccurate.
If the calibration data stored in the body control module is not received, the compass will read only
NE North-East. The CMTC is self calibrating and requires no adjusting. The word CAL is displayed
to show that the compass is in calibration mode. CAL will turn off after the vehicle has gone
through three complete circles without stopping, in an area free of magnetic disturbance. If module
displays temperature while the compass is blank, turn off ignition and run self diagnostics then
demagnetize the vehicle. If problem persists, then demagnetize vehicle.
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Testing and Inspection > Self-Check For Compass Mini-Trip (CMTC)
Compass: Testing and Inspection Self-Check For Compass Mini-Trip (CMTC)
The Compass Mini Trip Computer (CMTC) is capable of performing a diagnostic self check on
many of its internal functions. CMTC diagnostics may be performed using a scan tool and the
proper Body Control Module Testing and Inspection Procedures or by using the following
procedure.
1. With the ignition switch in the OFF position, press both the US/M and STEP buttons. 2. Turn
ignition switch to the ON position. The CMTC will perform internal checks while lighting all
segments of the vacuum florescent display.
Upon completion of the internal check the CMTC will display. PASS
- FAIL
- CCD
If any segment of the CMTC fails to light replace the module.
If FAIL is displayed replace the module.
If CCD is displayed check the CCD (Information Bus) and Body Control Module (BCM) for proper
operation. If the CCD bus and the BCM are OK, replace the CMTC module.
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
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Service and Repair > Compass Mini-Trip Computer (Cmtc) Module Replacement
Compass: Service and Repair Compass Mini-Trip Computer (Cmtc) Module Replacement
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. Refer to Body
and Frame/Interior Trim/Overhead Console Replacement.
Compass Mini-Trip Computer
3. Remove the six screws holding CMTC module to overhead console. 4. Remove CMTC module
from console.
INSTALLATION
For installation, reverse the above procedures.
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Compass: Service and Repair Compass Mini-Trip Computer (Cmtc) Lamp Bulbs
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. Refer to Body
and Frame/Interior Trim/Overhead Console Replacement.
CMTC Lamp Bulbs
3. Rotate bulb socket counterclockwise one quarter turn.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Compass Mini-Trip Computer (Cmtc) Module Replacement > Page 6679
Compass: Service and Repair Compass Calibration Procedure (Fast Method)
When the compass is subjected to excessive magnetic fields, the CMTC automatically enters a fast
calibration mode where is tries to compensate for the large magnetic shifts.
If the compass is inaccurate, appears to be inaccurate and the CAL is not illuminated the fast
calibration mode may be manually entered by using the following procedure.
1. Set the CMTC to Compass/Temperature mode and press the reset button for 10 continuous
seconds. Manual activation of the fast calibration is
generally not required.
2. Compass variance sets to the default of 8 after the fast calibration is manually activated. 3.
Complete the compass variance setting procedure by referring to the Compass Variance
Procedure. 4. Drive the vehicle in three 360° turns in an area free from large metal objects. If the
CAL symbol remains lit after completing this step, the roof
panel may need demagnetizing
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Compass Mini-Trip Computer (Cmtc) Module Replacement > Page 6680
Compass: Service and Repair Compass Calibration Procedure
Variance Settings
Variance is the difference between magnetic North and geographic North. To adjust the compass
variance set the CMTC to Compass/Temperature mode and press RESET buttons for 5 seconds.
The symbol VAR and the current variance zone number will be displayed. Press the STEP button
to select the proper variance zone. Press the US/Metric button to save the new vanance zone and
normal CMTC operation. If the RESET button is held for 10 seconds instead 5 seconds the CMTC
will set variance to 8 and enter the fast calibration mode.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6686
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
Negative Battery Cable
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering
column and at the lower edge of the lower instrument
panel.
2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the
proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative
terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and
record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any
diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper
Body
Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes
on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to
diagnose the problem.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations
Driver/Vehicle Information Display: Locations
Information Center
Information Center
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions
Driver/Vehicle Information Display: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6692
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6693
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6694
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
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Component Information > Diagrams > Diagram Information and Instructions > Page 6695
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Component Information > Diagrams > Diagram Information and Instructions > Page 6696
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6697
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6698
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6699
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6700
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6701
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6702
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6703
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Component Information > Diagrams > Diagram Information and Instructions > Page 6704
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6705
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6706
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Driver/Vehicle Information Display: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Component Information > Diagrams > Diagram Information and Instructions > Page 6710
Driver/Vehicle Information Display: Connector Views
Connector Pin Identification
Message Center
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Driver/Vehicle Information Display: Electrical Diagrams
Information Center
Wiring Diagrams
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Message Center -- Sheet 8w-46-2
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Message Center -- Sheet 8w-46-3
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6714
Message Center -- Sheet 8w-46-4
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6715
Message Center -- Sheet 8w-46-5
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 6716
Message Center -- Sheet 8w-46-6
NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams.
See: Diagrams/Electrical Diagrams/Diagrams By Group Number
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Page 6717
Driver/Vehicle Information Display: Description and Operation
The Overhead Console consists of a Compass/Mini-Trip Computer (CMTC), Universal Transmitter
and Reading/Dome lamps.
The CMTC consists of an electronic control module with a vacuum fluorescent display (VFD) and
function switches. The CMTC displays compass heading, trip computer with traveler messages,
and exterior temperature features. For more information on CMTC features, see Instrument
Panel/Compass, Outside Temperature Display, and Lighting/Dome Lamp.
The Universal Transmitter replaces the hand held remote controls that open the garage door,
motorized gates, or home lighting in/outside the home. This device memorizes the activator codes
for up to three remote controlled devices. It triggers those devices at the push of a button, located
in a unit permanently mounted in your overhead console (if equipped).
The transmitter operates off the vehicle's battery and charging system; no batteries are needed.
The Universal Transmitter incorporates a Rolling Code technology (random digital code signals
from the remote transmitter) within the transmitter module. This is done so as an added security
measure.
Features of the Universal Transmitter are:
^ Can be used with most other Radio Frequency (RF) activated devices.
^ Individual channels can be trained.
^ Stores transmitter data in permanent memory- retraining is not required even if the battery dies or
is disconnected.
To operate, simply press the appropriate button on the Universal Transmitter. The red LED will light
up while the signal is being transmitted.
NOTE: For security reasons, you are able to erase the trained frequencies.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Universal Transmitter Training and Erasing
Driver/Vehicle Information Display: Service and Repair Universal Transmitter Training and Erasing
Universal Transmitter
TRAINING
1. Turn off the engine. 2. Erase the factory test codes by pressing the two outside buttons. Release
the buttons when the red light begins to flash (about 20 seconds). 3. Choose one of the three
buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and
push the buttons on both
transmitters. The red light on the universal transmitter will begin to flash slowly.
4. When the red light on the universal transmitter begins to flash rapidly (this may take as long as
60 seconds), release both buttons. Your universal
transmitter is now "trained". To train the other buttons, repeat Step 3 and Step 4. Be sure to keep
your hand-held transmitter in case you need to retrain the universal transmitter.
ERASING
To erase the universal transmitter codes, simply hold down the two outside buttons until the red
LED begins to flash.
NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL
programmed codes.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Universal Transmitter Training and Erasing > Page 6720
Driver/Vehicle Information Display: Service and Repair Replacement
Universal Transmitter
REMOVAL
The Universal Transmitter is serviced with the transmitter bin door, in the overhead console.
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Open transmitter bin door in rear of
overhead console. 3. Gently pull towards rear of vehicle, releasing transmitter bin door. 4.
Disconnect harness connector from Universal Transmitter and remove bin door from vehicle.
INSTALLATION
For installation, reverse the above procedures. The Universal Transmitter will need to be retrained.
Refer to SERVICE PROCEDURES.
Message Center
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove A-pillar trim panel. 3. Remove
instrument panel top cover. Refer to Instrument Panel Top Cover Replacement. 4. Disconnect the
wire connector from back of message center 5. Remove screws holding message center to
instrument panel top cover.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Universal Transmitter Training and Erasing > Page 6721
6. Remove message center from instrument panel top cover.
INSTALLATION
1. Place message center in position on top cover. 2. Install screws to hold message center to
instrument panel top cover. 3. Connect wire connector into back of message center. 4. Install
instrument panel top cover. 5. Install A-pillar trim.
Message Center Lamp
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. Refer
to Instrument Panel Top Cover Replacement.
Message Center Lamp Location
3. Locate the lamp in question. 4. Remove lamp and check lamp. If lamp is good test the power
supply to the lamp.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Testing and Inspection > About Diagnostic Procedures
Fuel Gauge: Testing and Inspection About Diagnostic Procedures
Instrument Cluster DTC Table
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system
monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code
(DTC) will be displayed in the odometer window of the cluster.
The following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT, NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS
.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6734
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
Negative Battery Cable
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
1. Connect a DRB III scan tool to the Data Link connector, located at left side of the steering
column and at the lower edge of the lower instrument
panel.
2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the
proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative
terminal. 4. Using the DRB III® scan tool, read and record active diagnostic code data. 5. Read and
record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any
diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to the Proper
Body
Diagnostic Procedures to diagnose the problem. If airbag warning lamp either fails to light, or goes
on and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures to
diagnose the problem.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
This vehicle does not have a Maintenance Reminder Light option.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR (CHECK ENGINE) LAMP-PCM OUTPUT
The PCM supplies the malfunction indicator (check engine) lamp on/off signal to the instrument
panel through the CCD Bus. The CCD Bus is a communications port. Various modules use the
CCD Bus to exchange information.
The Check Engine lamp comes on each time the ignition key is turned ON and stays on for 3
seconds as a bulb test.
The Malfunction Indicator Lamp (MIL) stays on continuously, when the PCM has entered a Limp-In
mode or identified a failed emission component. During Limp-in Mode, the PCM attempts to keep
the system operational. The MIL signals the need for immediate service. In limp-in mode, the PCM
compensates for the failure of certain components that send incorrect signals. The PCM substitutes
for the incorrect signals with inputs from other sensors.
If the PCM detects active engine misfire severe enough to cause catalyst damage, it flashes the
MIL.
At the same time the PCM also sets a Diagnostic Trouble Code (DTC). For signals that can trigger
the MIL (Check Engine Lamp) refer to the On-Board Diagnostics Chart.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Testing and Inspection > About Diagnostic Procedures
Odometer: Testing and Inspection About Diagnostic Procedures
Instrument Cluster DTC Table
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system
monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code
(DTC) will be displayed in the odometer window of the cluster.
The following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 6745
Odometer: Testing and Inspection Odometer Diagnosis
Odometer Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 6746
Odometer Diagnosis (Part 2 Of 2)
When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate
sequentially. If a segment in the odometer does not illuminate normally, a problem exists in the
display.
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and
Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Testing and Inspection > Page 6747
Odometer: Service and Repair
REMOVAL
1. Remove instrument cluster. Refer to Instrument Cluster with Mechanical Transmission Range
Indicator Replacement. 2. Remove cluster lens. 3. Disconnect wire connector from odometer and
transmission range indicator. 4. Remove screws holding odometer and transmission range
indicator to cluster shell. 5. Remove odometer and transmission range indicator from cluster.
INSTALLATION
1. Install odometer and transmission range indicator and attach to cluster shell. 2. Connect wire
connector into odometer and transmission range indicator. 3. Install cluster lens. 4. Install
instrument cluster.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp >
Component Information > Description and Operation
Oil Change Reminder Lamp: Description and Operation
This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp >
Component Information > Description and Operation > Page 6751
Oil Change Reminder Lamp: Service and Repair
This Vehicle does not come equipped with an OIL CHANGE REMINDER LAMP.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Specifications
Oil Pressure Sender: Specifications
Oil Pressure Gauge Sending Unit 60 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Specifications > Page 6755
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Specifications > Page 6756
Oil Pressure Sender: Diagrams
Engine Oil Pressure Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside
Temperature Display Sensor > Component Information > Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Cigarette Lighter Relay > Component Information > Locations
Cigarette Lighter Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Cigarette Lighter Relay > Component Information > Locations > Page 6765
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Cigarette Lighter Relay > Component Information > Locations > Page 6766
Cigarette Lighter Relay: Diagrams
Power Distribution Center
Cigar Lighter/Accessory Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Outside Temperature Display Sensor > Component Information > Diagrams
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures
Speedometer Head: Testing and Inspection About Diagnostic Procedures
Instrument Cluster DTC Table
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system
monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code
(DTC) will be displayed in the odometer window of the cluster.
The following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures > Page 6778
Speedometer Head: Testing and Inspection Speedometer Diagnosis
Speedometer Diagnosis (Part 1 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures > Page 6779
Speedometer Diagnosis (Part 2 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures > Page 6780
Speedometer Diagnosis (Part 3 Of 3)
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and
Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures > Page 6781
Speedometer Head: Testing and Inspection Helpful Hints
ELECTRONIC PINION FACTOR
A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a
vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is
replaced, the electronic pinion factor must be programmed with the DRBIII (R) Scan Tool.
The nature of the Electronic Pinion Factor requires that certain features must be taken into
consideration: ^
If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed
when the vehicle is moving.
^ Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of
specification.
Use the following procedures to set the electronic pinion factor using the DRBIII (R) Scan Tool: ^
Select "Transmission" system, then "Miscellaneous" functions, the "Pinion Factor". The DRBIII (R)
will display the current tire size.
^ If the tire size is incorrect, depress the Enter key and then select the correct size.
^ Depress the Page Back key to exit the reset procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Description and Operation
Tachometer: Description and Operation
TACHOMETER-PCM OUTPUT
The PCM supplies engine RPM to the instrument panel tachometer through the CCD Bus. The
CCD Bus is a communications port. Various modules use the CCD Bus to exchange information.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection > About Diagnostic Procedures
Tachometer: Testing and Inspection About Diagnostic Procedures
Instrument Cluster DTC Table
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system
monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code
(DTC) will be displayed in the odometer window of the cluster.
The following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 6787
Tachometer: Testing and Inspection Tachometer Test
Tachometer Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 6788
Tachometer Diagnosis (Part 2 Of 2)
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and
Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Temperature Gauge: Initial Inspection and Diagnostic Overview
Instrument Cluster DTC Table
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system
monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code
(DTC) will be displayed in the odometer window of the cluster.
The following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6793
Temperature Gauge: Component Tests and General Diagnostics
Temperature Gauge Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6794
Temperature Gauge Diagnosis (Part 2 Of 2)
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and
Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Temperature Sender Unit 60 in.lb
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp >
Component Information > Testing and Inspection
Traction Control Indicator Lamp: Testing and Inspection
The traction control light is tested by cycling the traction control switch on and off. The traction
control switch used on this vehicle is a momentary contact type switch. The test procedure for the
traction control light is performed as follows: Press the traction control switch once and the TRAC
OFF lamp will illuminate. With the TRAC OFF lamp illuminated, press the traction control switch
again and the TRAC OFF lamp will turn off.
If the traction control lamp does not function as described in the test above, diagnosis of the
traction control switch, lamp, wiring and other related components of the traction control system is
required.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures
Transmission Shift Position Indicator Lamp: Testing and Inspection About Diagnostic Procedures
Instrument Cluster DTC Table
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform Self Diagnostic Test. The self diagnostic system
monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code
(DTC) will be displayed in the odometer window of the cluster.
The following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6805
Transmission Shift Position Indicator Lamp: Testing and Inspection Electronic Gear Indicator
Display Diagnostic Chart
Electronic Gear Indicator Display Diagnosis (Part 1 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6806
Electronic Gear Indicator Display Diagnosis (Part 2 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6807
Electronic Gear Indicator Display Diagnosis (Part 3 Of 3)
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and
Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 6808
Transmission Shift Position Indicator Lamp: Testing and Inspection Electronic Transmission Range
Indicator Segment Test
When CHEC-3 is displayed in the odometer window, each segment of the transmission range
indicator will illuminate sequentially. If a segment in the transmission range indicator does not
illuminate normally, a problem exists in the display board.
Conditions Refer to the following tables: Instrument Cluster
- Speedometer
- Tachometer
- Fuel Gauge
- Temperature Gauge
- Odometer
- Electronic Transmission Range Indicator (PRND3L)
- Mechanical Transmission Range Indicator (PRND21)
for possible/problems/causes and corrections.
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Cluster / Carrier/Testing and
Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > Page 6809
Transmission Shift Position Indicator Lamp: Service and Repair
REMOVAL
1. Remove instrument cluster. Refer to Instrument Cluster with Mechanical Transmission Range
Indicator Replacement. 2. Remove cluster lens. Refer to Instrument Cluster Lens Replacement. 3.
Remove screws holding mechanical transmission range indicator to back of cluster lens. 4.
Remove mechanical transmission range indicator from cluster lens.
INSTALLATION
1. Position transmission range indicator on cluster lens. 2. Install mechanical range indicator and
attaching screws to back of cluster lens. 3. Install cluster lens. 4. Install instrument cluster.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Diagrams
Backup Lamp Switch: Diagrams
For a three speed automatic please refer to: Starting and Charging, Starting System, Neutral
Safety Switch, See: Sensors and Switches/Sensors and Switches - Starting and Charging/Neutral
Safety Switch
For a four speed automatic please refer to: Transmission and Drivetrain, Automatic
Transmission/Transaxle, Sensors and Switches - A/T, Transmission Position Switch/Sensor, A/T,
See: Powertrain Management/Computers and Control Systems/Sensors and Switches - Computers
and Control Systems/Transmission Position Switch/Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service
and Repair
Backup Light Bulb: Service and Repair
REMOVAL
1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and
back-up lamp to rear door opening trough. 3. Remove inner end of lamp from quarter panel. 4.
Disengage hook holding outer end of lamp to quarter panel opening. 5. Remove lamp from quarter
panel.
Tail, Stop, Turn Signal And Back-up Lamp Bulb
6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp.
Pull Bulb From Socket
8. Pull bulb from socket.
INSTALLATION
1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back
of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of
lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold
lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and
Repair
Brake Light Bulb: Service and Repair
REMOVAL
1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and
back-up lamp to rear door opening trough. 3. Remove inner end of lamp from quarter panel. 4.
Disengage hook holding outer end of lamp to quarter panel opening. 5. Remove lamp from quarter
panel.
Tail, Stop, Turn Signal And Back-up Lamp Bulb
6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp.
Pull Bulb From Socket
8. Pull bulb from socket.
INSTALLATION
1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back
of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of
lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold
lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
Brake Light Switch: Locations
Brake Switch (Typical)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6825
Brake Light Switch: Diagrams
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6826
Brake Light Switch: Description and Operation
DESCRIPTION
The switch is mounted on the brake pedal mounting bracket under the instrument panel.
OPERATION
Vehicles equipped with the speed control option use a dual function stop lamp switch. The PCM
monitors the state of the dual function stop lamp switch. Refer to the stop lamp switch service and
adjustment procedures.
BRAKE SWITCH-PCM INPUT
When the brake switch is activated, the PCM receives an input indicating that the brakes are being
applied. After receiving this input the PCM maintains idle speed to a scheduled RPM through
control of the idle air control motor. The brake switch is mounted on the brake pedal support
bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6827
Brake Light Switch: Testing and Inspection
Stop Lamp Wiring
1. Remove the stop lamp switch refer to Stop Switch Replacement. Disconnect connector from
stop lamp switch. Using an ohmmeter, switch
continuity may be checked as follows:
2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch
plunger depressed, there should be continuity:
- Between Pin 1 and Pin 2.
- Between Pin 3 and Pin 4.
4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6828
Brake Light Switch: Adjustments
1. Remove stop lamp switch from its bracket by rotating it approximately 30 in a counter-clockwise
direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch
firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until
it has ratcheted out to
its fully extended position.
4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake
pedal as far down as possible. Then while keeping
the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on
switch with slot at top of square hole in mounting bracket. When switch is fully installed in the
square hole of the bracket, rotate switch clockwise approximately 30 to lock the switch into the
bracket.
Stop Light Switch Location In Vehicle
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can
result.
5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake
pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the
correct position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6829
Brake Light Switch: Service and Repair
REMOVAL
Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a
counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from
bracket. Disconnect wiring harness connector.
INSTALLATION
Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until
the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure.
Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch
with the plunger facing forward in car. There is an index key on the switch that mates with the
bracket slot at the top of the square hole. Align key and push switch into square hole in bracket
while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise
approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is
released. Pull back on the pedal to assure correct adjustment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb >
Component Information > Service and Repair
Center Mounted Brake Lamp Bulb: Service and Repair
REMOVAL
1. Release liftgate latch and open liftgate. 2. Disengage clips holding CHMSL access trim cover to
liftgate. 3. Remove trim cover from liftgate. 4. Rotate bulb socket counterclockwise one quarter
turn.
CHMSL Bulb
5. Pull socket from lamp. 6. Pull bulb from socket.
INSTALLATION
1. Insert bulb into socket. 2. Insert socket into lamp. 3. Rotate bulb socket clockwise one quarter
turn. 4. Place CHMSL access trim cover in position on liftgate. 5. Engage clips to hold access cover
to liftgate. 6. Verify CHMSL operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information >
Service and Repair > Front Door Courtesy Lamp Bulb
Courtesy Lamp Bulb: Service and Repair Front Door Courtesy Lamp Bulb
REMOVAL
Door Courtesy Lamp Lens
1. Using a small, flat bladed pry tool, pry rear edge of courtesy lamp lens from courtesy lamp. 2.
Remove lens from lamp. 3. Squeeze brass lamp bulb contacts together gently.
Door Courtesy Lamp Bulb
4. Disengage bulb from lamp contacts. 5. Remove bulb from lamp.
INSTALLATION
1. Position bulb to lamp contacts. 2. Engage bulb to lamp contacts. 3. Insert long edge of lens into
lamp housing. 4. Press on center of lens to engage remainder of clips.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information >
Service and Repair > Front Door Courtesy Lamp Bulb > Page 6839
Courtesy Lamp Bulb: Service and Repair Header Reading / Courtesy Lamp Bulb
REMOVAL
1. Insert a small, flat bladed pry tool at forward position between reading/courtesy lamp lens and
lamp housing.
Reading/Courtesy Lamp Lens
2. Pry lamp lens from lamp housing. 3. Insert a small, flat bladed pry tool between lamp light shield
and lamp housing at inboard rear corner of light shield.
Reading/Courtesy Lamp Light Shield
4. Pry light shield from housing. 5. Carefully press forward lamp bulb contact toward opposite
contact and rotate. 6. Remove bulb from lamp bulb contacts.
INSTALLATION
1. Carefully press forward lamp bulb contact toward opposite contact and rotate bulb into position.
2. Position bulb to lamp bulb contacts. 3. Release lamp bulb contacts. 4. Insert outer edge of light
shield into lamp housing. 5. Rotate light shield upward and snap inboard edge into lamp housing. 6.
Position lens switch tab to lamp switch. 7. Press lens pivots to tabs on lamp housing until both
pivots are seated.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information >
Service and Repair > Front Door Courtesy Lamp Bulb > Page 6840
Courtesy Lamp Bulb: Service and Repair Liftgate Courtesy Lamp Bulb
REMOVAL
1. Remove liftgate courtesy lamp. 2. Insert a small, flat bladed pry tool between courtesy lamp lens
and courtesy lamp body.
Liftgate Courtesy Lamp Bulb
3. Carefully depress tabs holding lens to courtesy lamp body. 4. Remove lamp lens from lamp
body. 5. Carefully press lamp bulb contact toward opposite contact. 6. Remove bulb from lamp
body.
INSTALLATION
1. Carefully press lamp bulb contact toward opposite contact. 2. Position bulb to lamp bulb
contacts. 3. Position long side of lamp lens to tabs on lamp body. 4. Press on center of lens to
engage tabs on opposite side of lamp body. 5. Install liftgate courtesy lamp.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information >
Service and Repair > Front Door Courtesy Lamp Bulb > Page 6841
Courtesy Lamp Bulb: Service and Repair Overhead Console Reading/Courtesy Lamp Bulb
REMOVAL
1. Using a trim stick, lightly pry outward the forward end of reading lamp lens. 2. Rotate reading
lamp bulb socket one quarter turn counterclockwise.
Reading/Courtesy Lamp
3. Pull socket out of lamp. 4. Pull bulb from socket.
INSTALLATION
1. Push bulb into socket. 2. Push socket into lamp. 3. Rotate reading lamp bulb socket one quarter
turn clockwise. 4. Insert tab on lamp lens between lamp switch and overhead console. 5. Snap lens
onto lamp lens pivots.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information >
Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information >
Locations > Page 6845
Courtesy Lamp Relay: Diagrams
Junction Block
Courtesy Lamp Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service
and Repair
Glove Box Lamp: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable.
Glove Box Lamp And Switch
2. Open glove box door. 3. Using a trim stick (special tool #C-4755), lightly pry glove box
lamp/switch from instrument panel. 4. Disengage wire connector from glove box lamp and switch.
5. Remove glove box lamp and switch.
Glove Box Lamp
6. Remove lamp.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service
and Repair > Page 6849
REMOVAL
1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument
panel.
Headlamp Switch
3. Disconnect wire connector from glove box lamp. 4. Remove glove box lamp from vehicle.
INSTALLATION
1. Position glove box lamp in vehicle. 2. Connect wire connector from glove box lamp. 3. Position
glove box lamp in instrument panel. 4. Press lamp into instrument panel until fully
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information >
Service and Repair
Glove Box Lamp Switch: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable.
Glove Box Lamp And Switch
2. Open glove box door. 3. Using a trim stick (special tool #C-4755), lightly pry glove box
lamp/switch from instrument panel. 4. Disengage wire connector from glove box lamp and switch.
5. Remove glove box lamp and switch.
Glove Box Lamp
6. Remove lamp.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information >
Service and Repair > Page 6853
REMOVAL
1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument
panel.
Glove Box Lamp And Switch
3. Disconnect wire connector from glove box lamp. 4. Remove glove box lamp from vehicle.
INSTALLATION
1. Position glove box lamp in vehicle. 2. Connect wire connector from glove box lamp. 3. Position
glove box lamp in instrument panel. 4. Press lamp into instrument panel until fully
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Description and Operation
Daytime Running Lamp Control Unit: Description and Operation
SYSTEM OPERATION
Combination Flasher / Daytime Running Lamps (DRL) Module
Junction Block Terminal Pins
The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime
running light functions, and has been designed with internal relays to take advantage of low current
switching requirements in the vehicle. It is plugged into the junction block at positions 3 AND 4
where all wiring associated with its operation is terminated. The Junction Block is adjacent to and
left of the steering column of the vehicle.
To gain access to the device, remove the lower steering column cover and knee blocker, refer to
Instrument Panel and Systems.
The combination flasher/DRL may be operated in its hazard warning mode either with or without
the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL
mode, the ignition circuit must be completed to the module.
While the combination flasher portion is idle, there is no current drawn through the module. The
device does not become active in the turn signal or hazard warning modes until a signal ground
circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition
OFF, there is no current drawn through the module.
While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by applying a signal ground input from either the
park brake circuit or the headlamp relay activation circuit.
Typical flash rate for the flasher is 90 flashes per minute.
When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate
will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning
signal mode the flash rate remains at 90 flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of
300 mA., and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
that could draw a maximum of 600 mA. through the multi-function switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Description and Operation > Page 6858
Daytime Running Lamp Control Unit: Testing and Inspection
Electronic Combination Flasher Circuit
Electronic Combination Flasher With DRL Circuit
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through
a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This
circuit (L09) is the only power feed to the combination-flasher/ DRL.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Description and Operation > Page 6859
Junction Block Terminal Call-Out
Junction Block Terminal Call-Out With DRL
The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal
Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems
with Ignition voltage if the vehicle is so equipped:
- Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically
5 mA of current while active.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Description and Operation > Page 6860
Combination Flasher Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Description and Operation > Page 6861
Combination Flasher Diagnosis (Part 2 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Description and Operation > Page 6862
Combination Flasher Diagnosis With DRL (Part 1 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Description and Operation > Page 6863
Combination Flasher Diagnosis With DRL (Part 2 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Description and Operation > Page 6864
Combination Flasher Diagnosis With DRL (Part 3 Of 3)
For diagnostic test procedures, refer to Combination Flasher Diagnosis tables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and
Repair > Rail Lamp Module Bulb
Dome Lamp Bulb: Service and Repair Rail Lamp Module Bulb
REMOVAL
Rail Lamp Module Lens
1. Using a small screw driver, pry stationary end of rail lamp lens from rail lamp module. 2. Remove
lens tab from between rail lamp module and rail lamp switch. 3. Remove lens from lamp.
Rail Lamp Module Bulb
4. Pull bulb from lamp.
INSTALLATION
1. Push bulb into bulb contacts in rail lamp module. 2. Insert tab on lamp lens between rail lamp
module and rail lamp switch. 3. Snap lens onto lens pivots on module.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and
Repair > Rail Lamp Module Bulb > Page 6870
Dome Lamp Bulb: Service and Repair Dome Lamp Bulb
REMOVAL
1. Insert a small, flat bladed pry tool between dome lamp lens and dome lamp body on left side of
dome lamp.
Dome Lamp Bulb
2. Disengage left side of dome lamp lens from lamp body. 3. Pull bulb from lamp socket.
INSTALLATION
1. Push bulb into lamp socket. 2. Pivot dome lamp lens upward. Verify that lamp lens hook is above
the headlining. 3. Engage left side of dome lamp lens to lamp body.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6879
Hazard Warning Flasher: Diagrams
Junction Block
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6880
Combination Flasher
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6881
Hazard Warning Flasher: Description and Operation
SYSTEM OPERATION
Combination Flasher Function The Turn Signal/Hazard Warning Flasher is a module providing turn
signal, hazard warning functions and has been designed with internal relays to take advantage of
low current switching requirements in the vehicle. It is plugged into the Junction Block at positions 4
where all wiring associated with its operation is terminated. The Junction Block is adjacent to and
left of the steering column of the vehicle.
To gain access to the device, remove the lower steering column cover and knee blocker, refer to
Instrument Panel and Systems.
The combination flasher may be operated in its hazard warning mode either with or without the
ignition circuit being active. However, in order to operate in the turn signal mode, the ignition circuit
must be completed to the module.
While the combination flasher is idle, there is no current drawn through the module. The device
does not become active until a signal ground circuit is supplied to either of the turn signal inputs or
the hazard warning input.
Typical flash rate for the flasher is 90 flashes per minute.
When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate
will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning
signal mode the flash rate remains at 90 flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each drawing a maximum of
300 mA., and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
drawing a maximum of 600 mA. through the multi-function switch.
Combination Flasher / Daytime Running Lamps (DRL) Module
Junction Block Terminal Pins
The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime
running light functions, and has been designed with internal relays to take advantage of low current
switching requirements in the vehicle. It is plugged into the junction block at positions 3 AND 4
where all wiring associated with its operation is terminated. The Junction Block is adjacent to and
left of the steering column of the vehicle.
To gain access to the device, remove the lower steering column cover and knee blocker, refer to
Instrument Panel and Systems.
The combination flasher/DRL may be operated in its hazard warning mode either with or without
the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL
mode, the ignition circuit must be completed to the module.
While the combination flasher portion is idle, there is no current drawn through the module. The
device does not become active in the turn signal or hazard warning modes until a signal ground
circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition
OFF, there is no current drawn through the module.
While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by applying a signal ground input from either the
park brake circuit or the headlamp relay activation circuit.
Typical flash rate for the flasher is 90 flashes per minute.
When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate
will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning
signal mode the flash rate remains at 90 flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of
300 mA., and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
that could draw a maximum of 600 mA. through the multi-function switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6882
Hazard Warning Flasher: Testing and Inspection
Electronic Combination Flasher Circuit
Electronic Combination Flasher With DRL Circuit
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through
a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This
circuit (L09) is the only power feed to the combination-flasher/ DRL.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6883
Junction Block Terminal Call-Out
Junction Block Terminal Call-Out With DRL
The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal
Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems
with Ignition voltage if the vehicle is so equipped:
- Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically
5 mA of current while active.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6884
Combination Flasher Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6885
Combination Flasher Diagnosis (Part 2 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6886
Combination Flasher Diagnosis With DRL (Part 1 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6887
Combination Flasher Diagnosis With DRL (Part 2 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6888
Combination Flasher Diagnosis With DRL (Part 3 Of 3)
For diagnostic test procedures, refer to Combination Flasher Diagnosis tables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 6889
Hazard Warning Flasher: Service and Repair
Combination Flasher With/Without DRL Module
REMOVAL
Battery Negative Cable
1. Disconnect and isolate battery negative cable. 2. Remove lower steering column cover. Refer to
Instrument Panel and Systems for Replacement. 3. Remove knee blocker. Refer to Instrument
Panel and Systems for Removal and Installation. 4. Pull combination flasher from junction block.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams
Multi-Function Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Page 6893
Hazard Warning Switch: Testing and Inspection
To test turn signal, headlamp beam select and optical horn portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Turn Signal - Multi-Function Switch Pin Numbers
2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the
above image for proper pin numbers and Turn
Signal Multi-Function Switch Test table.
TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between
Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Page 6894
Hazard Warning Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR PROPER AND SAFE SERVICE
PROCEDURES.
REMOVAL 1. Release hood latch and open hood.
Battery Negative Cable
2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column
shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For installation, reverse the above procedures. Verify switch operation by placing
the control stalk in either the right or left position and turning the steering wheel to ensure the
automatic cancellation of the switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair
Headlamp Bulb: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. From behind radiator closure panel, disconnect wire
connector from back of headlamp bulb base. 3. Rotate headlamp bulb retaining ring
counterclockwise.
Headlamp Bulb
4. Remove retaining ring from headlamp. 5. Pull headlamp bulb from back of headlamp.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface,
reduced bulb life will result.
1. From behind radiator closure panel, insert headlamp bulb into back of headlamp. 2. Engage
retaining ring onto headlamp. 3. Rotate headlamp bulb retaining ring clockwise. 4. Connect wire
connector into headlamp bulb base. 5. Verify headlamp alignment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information >
Technical Service Bulletins > Recalls for Headlamp Control Module: > NHTSA99V116000 > May > 99 > Recall 99V116000:
Headlamp Module Defect
Headlamp Control Module: Recalls Recall 99V116000: Headlamp Module Defect
Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL"
as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment."
These vehicles do not comply with requirements of FMVSS No. 108.
All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters.
Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on
an agreed upon service date and do not receive the free remedy within a reasonable time should
contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Headlamp Control Module: > NHTSA99V116000 > May >
99 > Recall 99V116000: Headlamp Module Defect
Headlamp Control Module: All Technical Service Bulletins Recall 99V116000: Headlamp Module
Defect
Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL"
as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment."
These vehicles do not comply with requirements of FMVSS No. 108.
All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters.
Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on
an agreed upon service date and do not receive the free remedy within a reasonable time should
contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations
Headlamp Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations >
Page 6915
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations >
Page 6916
Headlamp Relay: Diagrams
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations >
Page 6917
Power Distribution Center -- Sheet 8w-10-6
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams
Headlamp Switch: Diagrams
Headlamp Switch C1
Headlamp Switch C2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 6921
Headlamp Switch: Testing and Inspection
Headlamp Switch Continuity
Rheostat Continuity
Headlamp Switch Connectors (Switch Side)
Using a Digital Multimeter equipped with a diode test, perform the Headlamp Switch Continuity test
and the Rheostat Continuity test.
Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within
specifications replace as necessary.
The Chrysler Town and Country is available with optional Automatic Headlamps. For diagnosis,
refer to the proper Body Diagnostic Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and
Repair > Headlight Switch
Headlamp Switch: Service and Repair Headlight Switch
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable.
Headlamp Switch
2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. 3. Remove
screws holding the headlamp switch bezel to cluster bezel. 4. Disconnect the wire connectors from
the headlamp switch and wire connector from the power mirror switch. 5. Remove headlamp switch
bezel from cluster bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and
Repair > Headlight Switch > Page 6924
Headlamp Switch: Service and Repair Headlight Switch Lamp
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. 3.
Disconnect wire connectors. 4. Remove headlamp switch bezel from instrument cluster bezel.
Headlamp Switch Lamp
5. Rotate bulb socket counterclockwise one quarter turn. 6. Pull bulb socket from headlamp switch.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Diagrams
High Beam Relay: Diagrams
Power Distribution Center
High Beam Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Diagrams
Low Beam Relay: Diagrams
Power Distribution Center
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Diagrams >
Page 6931
Low Beam Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Horn Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6936
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6937
Horn Relay: Diagrams
Power Distribution Center
Horn Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6938
Horn Relay: Testing and Inspection
1. Remove horn relay.
Horn Relay
2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance.
If resistance not OK, replace relay 3. Test for continuity between ground and terminal 85 of horn
relay.
a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground
when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as
necessary, refer to Passive Restraints for Driver's Airbag Module Replacement.
4. Using voltmeter, test voltage at:
a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM.
c. If incorrect voltage repair as necessary.
5. Insert a jumper wire between terminal 30 and 87 of the power distribution center.
a. If horn sounds replace relay b. If the horn does not sound, install horn relay and refer to Horn
Test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations
Speed Control Switches
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 6942
Horn Switch: Service and Repair
REMOVAL AND INSTALLATION
The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately.
Refer to Passive Restraints for Driver Airbag Module Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Service and Repair
Key Cylinder Lamp: Service and Repair
Ignition Halo Lamp Bulb
REMOVAL
1. Remove steering column trim covers.
Ignition Halo Lamp Bulb
2. Rotate bulb socket counterclockwise one quarter turn. 3. Pull bulb socket from halo lamp.
INSTALLATION
1. Push bulb socket into halo lamp. 2. Rotate bulb socket clockwise one quarter turn. 3. Install
steering column trim covers.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information >
Service and Repair
License Plate Bulb: Service and Repair
REMOVAL
1. Remove screws attaching license plate lamp lens to liftgate. 2. Remove license plate lamp lens
from lamp. 3. Rotate lamp socket counterclockwise one quarter turn.
License Plate Lamp Bulb
4. Pull socket from lens. 5. Pull bulb from socket.
INSTALLATION
1. Install bulb into socket. 2. Insert socket into lens. 3. Rotate lamp socket clockwise one quarter
turn. 4. Place license plate lamp lens in position in lamp. 5. Install screws attaching license plate
lamp lens. 6. Verify license plate lamp operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and
Repair > Header Reading/Courtesy Lamp Bulb
Map Light Bulb: Service and Repair Header Reading/Courtesy Lamp Bulb
REMOVAL
1. Insert a small, flat bladed pry tool at forward position between reading/courtesy lamp lens and
lamp housing.
Reading/Courtesy Lamp Lens
2. Pry lamp lens from lamp housing. 3. Insert a small, flat bladed pry tool between lamp light shield
and lamp housing at inboard rear corner of light shield.
Reading/Courtesy Lamp Light Shield
4. Pry light shield from housing. 5. Carefully press forward lamp bulb contact toward opposite
contact and rotate. 6. Remove bulb from lamp bulb contacts.
INSTALLATION
1. Carefully press forward lamp bulb contact toward opposite contact and rotate bulb into position.
2. Position bulb to lamp bulb contacts. 3. Release lamp bulb contacts. 4. Insert outer edge of light
shield into lamp housing. 5. Rotate light shield upward and snap inboard edge into lamp housing. 6.
Position lens switch tab to lamp switch. 7. Press lens pivots to tabs on lamp housing until both
pivots are seated.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and
Repair > Header Reading/Courtesy Lamp Bulb > Page 6955
Map Light Bulb: Service and Repair Overhead Console Reading/Courtesy Lamp Bulb
REMOVAL
1. Using a trim stick, lightly pry outward the forward end of reading lamp lens. 2. Rotate reading
lamp bulb socket one quarter turn counterclockwise.
Reading/Courtesy Lamp
3. Pull socket out of lamp. 4. Pull bulb from socket.
INSTALLATION
1. Push bulb into socket. 2. Push socket into lamp. 3. Rotate reading lamp bulb socket one quarter
turn clockwise. 4. Insert tab on lamp lens between lamp switch and overhead console. 5. Snap lens
onto lamp lens pivots.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information >
Locations
Parking Lamp Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information >
Locations > Page 6960
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information >
Locations > Page 6961
Parking Lamp Relay: Diagrams
Power Distribution Center
Park Lamp Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Component Information > Locations > Page 6966
Courtesy Lamp Relay: Diagrams
Junction Block
Courtesy Lamp Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation
Daytime Running Lamp Control Unit: Description and Operation
SYSTEM OPERATION
Combination Flasher / Daytime Running Lamps (DRL) Module
Junction Block Terminal Pins
The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime
running light functions, and has been designed with internal relays to take advantage of low current
switching requirements in the vehicle. It is plugged into the junction block at positions 3 AND 4
where all wiring associated with its operation is terminated. The Junction Block is adjacent to and
left of the steering column of the vehicle.
To gain access to the device, remove the lower steering column cover and knee blocker, refer to
Instrument Panel and Systems.
The combination flasher/DRL may be operated in its hazard warning mode either with or without
the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL
mode, the ignition circuit must be completed to the module.
While the combination flasher portion is idle, there is no current drawn through the module. The
device does not become active in the turn signal or hazard warning modes until a signal ground
circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition
OFF, there is no current drawn through the module.
While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by applying a signal ground input from either the
park brake circuit or the headlamp relay activation circuit.
Typical flash rate for the flasher is 90 flashes per minute.
When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate
will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning
signal mode the flash rate remains at 90 flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of
300 mA., and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
that could draw a maximum of 600 mA. through the multi-function switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 6970
Daytime Running Lamp Control Unit: Testing and Inspection
Electronic Combination Flasher Circuit
Electronic Combination Flasher With DRL Circuit
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through
a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This
circuit (L09) is the only power feed to the combination-flasher/ DRL.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 6971
Junction Block Terminal Call-Out
Junction Block Terminal Call-Out With DRL
The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal
Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems
with Ignition voltage if the vehicle is so equipped:
- Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically
5 mA of current while active.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 6972
Combination Flasher Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 6973
Combination Flasher Diagnosis (Part 2 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 6974
Combination Flasher Diagnosis With DRL (Part 1 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 6975
Combination Flasher Diagnosis With DRL (Part 2 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Description and Operation > Page 6976
Combination Flasher Diagnosis With DRL (Part 3 Of 3)
For diagnostic test procedures, refer to Combination Flasher Diagnosis tables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module >
Component Information > Technical Service Bulletins > Recalls for Headlamp Control Module: > NHTSA99V116000 > May
> 99 > Recall 99V116000: Headlamp Module Defect
Headlamp Control Module: Recalls Recall 99V116000: Headlamp Module Defect
Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL"
as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment."
These vehicles do not comply with requirements of FMVSS No. 108.
All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters.
Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on
an agreed upon service date and do not receive the free remedy within a reasonable time should
contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headlamp Control Module: >
NHTSA99V116000 > May > 99 > Recall 99V116000: Headlamp Module Defect
Headlamp Control Module: All Technical Service Bulletins Recall 99V116000: Headlamp Module
Defect
Mini vans built for fleet sales only. The Headlamp module does not identify the park lamp as "DRL"
as requirement of FMVSS 108, "Lamps, Reflective Devices, and Associated Equipment."
These vehicles do not comply with requirements of FMVSS No. 108.
All fleet owners/operators will be mailed non-removable decals with the required "DRL" letters.
Owner notification began May 31, 1999. Owners who take their vehicles to an authorized dealer on
an agreed upon service date and do not receive the free remedy within a reasonable time should
contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations
Headlamp Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations > Page 6996
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations > Page 6997
Headlamp Relay: Diagrams
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations > Page 6998
Power Distribution Center -- Sheet 8w-10-6
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay >
Component Information > Diagrams
High Beam Relay: Diagrams
Power Distribution Center
High Beam Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Horn Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 7005
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 7006
Horn Relay: Diagrams
Power Distribution Center
Horn Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 7007
Horn Relay: Testing and Inspection
1. Remove horn relay.
Horn Relay
2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance.
If resistance not OK, replace relay 3. Test for continuity between ground and terminal 85 of horn
relay.
a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground
when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as
necessary, refer to Passive Restraints for Driver's Airbag Module Replacement.
4. Using voltmeter, test voltage at:
a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM.
c. If incorrect voltage repair as necessary.
5. Insert a jumper wire between terminal 30 and 87 of the power distribution center.
a. If horn sounds replace relay b. If the horn does not sound, install horn relay and refer to Horn
Test.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Diagrams
Low Beam Relay: Diagrams
Power Distribution Center
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay >
Component Information > Diagrams > Page 7011
Low Beam Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Parking Lamp Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Page 7015
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Page 7016
Parking Lamp Relay: Diagrams
Power Distribution Center
Park Lamp Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams
Backup Lamp Switch: Diagrams
For a three speed automatic please refer to: Starting and Charging, Starting System, Neutral
Safety Switch, See: Sensors and Switches/Sensors and Switches - Starting and Charging/Neutral
Safety Switch
For a four speed automatic please refer to: Transmission and Drivetrain, Automatic
Transmission/Transaxle, Sensors and Switches - A/T, Transmission Position Switch/Sensor, A/T,
See: Powertrain Management/Computers and Control Systems/Sensors and Switches - Computers
and Control Systems/Transmission Position Switch/Sensor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
Brake Switch (Typical)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 7024
Brake Light Switch: Diagrams
Connector Pin Identification
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 7025
Brake Light Switch: Description and Operation
DESCRIPTION
The switch is mounted on the brake pedal mounting bracket under the instrument panel.
OPERATION
Vehicles equipped with the speed control option use a dual function stop lamp switch. The PCM
monitors the state of the dual function stop lamp switch. Refer to the stop lamp switch service and
adjustment procedures.
BRAKE SWITCH-PCM INPUT
When the brake switch is activated, the PCM receives an input indicating that the brakes are being
applied. After receiving this input the PCM maintains idle speed to a scheduled RPM through
control of the idle air control motor. The brake switch is mounted on the brake pedal support
bracket.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 7026
Brake Light Switch: Testing and Inspection
Stop Lamp Wiring
1. Remove the stop lamp switch refer to Stop Switch Replacement. Disconnect connector from
stop lamp switch. Using an ohmmeter, switch
continuity may be checked as follows:
2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch
plunger depressed, there should be continuity:
- Between Pin 1 and Pin 2.
- Between Pin 3 and Pin 4.
4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 7027
Brake Light Switch: Adjustments
1. Remove stop lamp switch from its bracket by rotating it approximately 30 in a counter-clockwise
direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch
firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until
it has ratcheted out to
its fully extended position.
4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake
pedal as far down as possible. Then while keeping
the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on
switch with slot at top of square hole in mounting bracket. When switch is fully installed in the
square hole of the bracket, rotate switch clockwise approximately 30 to lock the switch into the
bracket.
Stop Light Switch Location In Vehicle
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can
result.
5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake
pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the
correct position.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 7028
Brake Light Switch: Service and Repair
REMOVAL
Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a
counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from
bracket. Disconnect wiring harness connector.
INSTALLATION
Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until
the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure.
Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch
with the plunger facing forward in car. There is an index key on the switch that mates with the
bracket slot at the top of the square hole. Align key and push switch into square hole in bracket
while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise
approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is
released. Pull back on the pedal to assure correct adjustment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 7037
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 7038
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 7039
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 7040
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 7041
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 7042
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7048
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7049
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7050
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7051
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7052
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7053
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch >
Component Information > Service and Repair
Glove Box Lamp Switch: Service and Repair
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable.
Glove Box Lamp And Switch
2. Open glove box door. 3. Using a trim stick (special tool #C-4755), lightly pry glove box
lamp/switch from instrument panel. 4. Disengage wire connector from glove box lamp and switch.
5. Remove glove box lamp and switch.
Glove Box Lamp
6. Remove lamp.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch >
Component Information > Service and Repair > Page 7057
REMOVAL
1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument
panel.
Glove Box Lamp And Switch
3. Disconnect wire connector from glove box lamp. 4. Remove glove box lamp from vehicle.
INSTALLATION
1. Position glove box lamp in vehicle. 2. Connect wire connector from glove box lamp. 3. Position
glove box lamp in instrument panel. 4. Press lamp into instrument panel until fully
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams
Multi-Function Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 7061
Hazard Warning Switch: Testing and Inspection
To test turn signal, headlamp beam select and optical horn portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Turn Signal - Multi-Function Switch Pin Numbers
2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the
above image for proper pin numbers and Turn
Signal Multi-Function Switch Test table.
TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between
Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 7062
Hazard Warning Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS/AIR BAGS FOR PROPER AND SAFE SERVICE
PROCEDURES.
REMOVAL 1. Release hood latch and open hood.
Battery Negative Cable
2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column
shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For installation, reverse the above procedures. Verify switch operation by placing
the control stalk in either the right or left position and turning the steering wheel to ensure the
automatic cancellation of the switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams
Headlamp Switch: Diagrams
Headlamp Switch C1
Headlamp Switch C2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 7066
Headlamp Switch: Testing and Inspection
Headlamp Switch Continuity
Rheostat Continuity
Headlamp Switch Connectors (Switch Side)
Using a Digital Multimeter equipped with a diode test, perform the Headlamp Switch Continuity test
and the Rheostat Continuity test.
Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within
specifications replace as necessary.
The Chrysler Town and Country is available with optional Automatic Headlamps. For diagnosis,
refer to the proper Body Diagnostic Procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Service and Repair > Headlight Switch
Headlamp Switch: Service and Repair Headlight Switch
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable.
Headlamp Switch
2. Remove instrument cluster bezel. Refer to Instrument Cluster Bezel Replacement. 3. Remove
screws holding the headlamp switch bezel to cluster bezel. 4. Disconnect the wire connectors from
the headlamp switch and wire connector from the power mirror switch. 5. Remove headlamp switch
bezel from cluster bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Service and Repair > Headlight Switch > Page 7069
Headlamp Switch: Service and Repair Headlight Switch Lamp
REMOVAL
Battery Negative Cable
1. Disconnect and isolate the battery negative cable. 2. Remove instrument cluster bezel. 3.
Disconnect wire connectors. 4. Remove headlamp switch bezel from instrument cluster bezel.
Headlamp Switch Lamp
5. Rotate bulb socket counterclockwise one quarter turn. 6. Pull bulb socket from headlamp switch.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Locations
Speed Control Switches
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Locations > Page 7073
Horn Switch: Service and Repair
REMOVAL AND INSTALLATION
The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately.
Refer to Passive Restraints for Driver Airbag Module Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams
Multi-Function Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 7077
Turn Signal Switch: Testing and Inspection
To test turn signal, headlamp beam select and optical horn portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Turn Signal - Multi-Function Switch Pin Numbers
2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the
above image for proper pin numbers and Turn
Signal Multi-Function Switch Test table.
TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between
Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 7078
Turn Signal Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable.
3. Remove upper and lower steering column shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and
Repair
Tail Light Bulb: Service and Repair
REMOVAL
1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and
back-up lamp to rear door opening trough. 3. Remove inner end of lamp from quarter panel. 4.
Disengage hook holding outer end of lamp to quarter panel opening. 5. Remove lamp from quarter
panel.
Tail, Stop, Turn Signal And Back-up Lamp Bulb
6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp.
Pull Bulb From Socket
8. Pull bulb from socket.
INSTALLATION
1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back
of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of
lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold
lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7092
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7093
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7094
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7095
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7096
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7097
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 7103
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 7104
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 7105
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 7106
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 7107
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 7108
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Locations
Combination Flasher Location
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions
Turn Signal Flasher: Diagram Information and Instructions
Introduction
General Information (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 7114
General Information (Part 2 Of 2)
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 7115
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
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Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 7116
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 7117
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
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Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 7118
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
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junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
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Diagrams > Diagram Information and Instructions > Page 7120
Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location to indicate a point at which the wiring
harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
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Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
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1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
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Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
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Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
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10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
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Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
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Diagrams > Diagram Information and Instructions > Page 7127
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
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Diagrams > Diagram Information and Instructions > Page 7128
Terminal Removing Tool 6932
Terminal Removing Tool 6934
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Turn Signal Flasher: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
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Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
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3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
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Turn Signal Flasher: Connector Views
Junction Block Terminal Pins
Junction Block Terminal Call-Out With DRL
Junction Block Terminal Pins
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Junction Block Terminal Call-Out
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Turn Signal Flasher: Electrical Diagrams
Electronic Combination Flasher With DRL Circuit
Junction Block Terminal Call-Out With DRL
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Electronic Combination Flasher Circuit
Junction Block Terminal Call-Out
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Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL)
Turn Signal Flasher: Description and Operation Combination Flasher -- With Daytime Running
Lamps (DRL)
Combination Flasher Location
SYSTEM OPERATION
The turn signals are actuated with a lever on the left side of the steering column just ahead of the
steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to
the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn
signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns
the switch to the OFF position.
Lane change signaling is actuated by applying partial turn signal stalk movement toward the
direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is
released the stalk will spring back into the neutral position turning OFF the turn signal.
With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows
through the: Combination flasher
- Multi-function switch
- Turn indicator lamp
- Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn
signal ON.
FLASHER MODULE DESCRIPTION
The Turn Signal/Hazard Warning Flasher is a module providing the vehicle with turn signal and
hazard warning functions and has been designed with internal relays to take advantage of low
current switching requirements in the vehicle. It is plugged into the Junction Block at position 4,
where all wiring associated with its operation is terminated.
The Junction Block is adjacent to and left of the steering column of the vehicle.
To gain access to the flasher, remove the lower steering column cover and knee blocker.
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Junction Block Terminal Pins
FLASHER MODULE OPERATION
The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime
running light functions, and has been designed with internal relays to take advantage of low current
switching requirements in the vehicle. It is plugged into the junction block at positions 3 and 4
where all wiring associated with its operation is terminated. The Junction Block is adjacent to and
left of the steering column of the vehicle. To gain access to the device, remove the lower steering
column cover and knee blocker.
The combination flasher/DRL may be operated in its hazard warning mode either with or without
the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL
mode, the ignition circuit must be completed to the module.
While the combination flasher portion is idle, there is no current drawn through the module. The
device does not become active in the turn signal or hazard warning modes until a signal ground
circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition
OFF, there is no current drawn through the module.
While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by applying a signal ground input from either the
park brake circuit or the headlamp relay activation circuit.
Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side
of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute
when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90
flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of
300 mA, and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
that could draw a maximum of 600 mA. through the multi-function switch.
Electronic Combination Flasher With DRL Circuit
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Junction Block Terminal Call-Out With DRL
CIRCUIT OPERATION
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC)
through a 20 ampere fuse at position 15 (5th position from the upper end) and labeled HAZARD.
This circuit (L09) is the only power feed to the combination-flasher/DRL.
The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D.
This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is
so equipped: Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil
The ignition input to the combo-flasher will draw typically 5 mA of current while active.
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Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 7140
Turn Signal Flasher: Description and Operation Combination Flasher -- Without Daytime Running
Lamps (DRL)
Combination Flasher Location
SYSTEM OPERATION
The turn signals are actuated with a lever on the left side of the steering column just ahead of the
steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to
the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn
signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns
the switch to the OFF position.
Lane change signaling is actuated by applying partial turn signal stalk movement toward the
direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is
released the stalk will spring back into the neutral position turning OFF the turn signal.
With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows
through the: Combination flasher
- Multi-function switch
- Turn indicator lamp
- Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn
signal ON.
FLASHER MODULE DESCRIPTION
The Turn Signal/Hazard Warning Flasher is a module providing the vehicle with turn signal and
hazard warning functions and has been designed with internal relays to take advantage of low
current switching requirements in the vehicle. It is plugged into the Junction Block at position 4,
where all wiring associated with its operation is terminated.
The Junction Block is adjacent to and left of the steering column of the vehicle.
To gain access to the flasher, remove the lower steering column cover and knee blocker.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 7141
Junction Block Terminal Pins
FLASHER MODULE OPERATION
The Turn Signal/Hazard Warning Flasher is a module providing turn signal, hazard warning
functions and has been designed with internal relays to take advantage of low current switching
requirements in the vehicle. It is plugged into the Junction Block at position 4 where all wiring
associated with its operation is terminated. The Junction Block is adjacent to and left of the steering
column of the vehicle.
To gain access to the device, remove the lower steering column cover and knee blocker.
The combination flasher may be operated in its hazard warning mode either with or without the
ignition circuit being active. However, in order to operate in the turn signal mode, the ignition circuit
must be completed to the module.
While the combination flasher is idle, there is no current drawn through the module. The device
does not become active until a signal ground circuit is supplied to either of the turn signal inputs or
the hazard warning input.
Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side
of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute
when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90
flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each drawing a maximum of
300 mA and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
drawing a maximum of 600 mA through the multi-function switch.
Electronic Combination Flasher Circuit
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Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 7142
Junction Block Terminal Call-Out
CIRCUIT OPERATION
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC)
through a 20 ampere fuse at position 15 (5th position from the upper end) and labeled HAZARD.
This circuit (L09) is the only power feed to the combination-flasher/DRL.
The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D.
This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is
so equipped: Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil
The ignition input to the combo-flasher will draw typically 5 mA of current while active.
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Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 7143
Turn Signal Flasher: Description and Operation Combination Flasher Operation
SYSTEM OPERATION
The turn signals are actuated with a lever on the left side of the steering column just ahead of the
steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to
the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn
signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns
the switch to the OFF position.
Lane change signaling is actuated by applying partial turn signal stalk movement toward the
direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is
released the stalk will spring back into the neutral position turning OFF the turn signal.
With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows
through the: Combination flasher
- Multi-function switch
- Turn indicator lamp
- Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn
signal ON.
Circuit Operation The turn signal and hazard flasher system used in this vehicle is controlled by the
combination flasher located in the junction block. On vehicles built for sale in Canada the Daytime
Running Lamp (DRL) module is part of the combination flasher.
Power for the combination flasher is supplied from two sources. One is a direct battery feed on
circuit L9. This circuit is HOT at all times and protected by a 20 Amp fuse located in cavity 19 of the
Power Distribution Center (PDC).
The other power source is a fuse battery feed from the ignition switch on circuit F20. This circuit is
HOT in the RUN position only and connects from the ignition switch to the combination flasher.
Power for the F20 circuit is supplied on circuit A22/A2. This circuit originates at the PDC and is
protected by a 40 Amp fuse located in cavity 2.
LEFT TURN SIGNALS
Circuit Operation When the operator selects the left turn signal, circuit L305 is connected to the Z1
ground circuit through the turn signal switch.
The combination flasher senses the position of the switch and supplies power to the L61 and L63
circuits.
Circuit L61 connects from the combination flasher to the left front turn signal lamp. Ground for the
lamp is supplied on circuit Z1 and terminates at the left cowl panel.
Circuit L63 connects from the combination flasher to the left rear turn signal lamp. Ground for the
lamp is supplied on circuit Z1 and terminates at the rear body ground. This circuit is also spliced
and provides an input to the Body Control Module (BCM) to indicate the turn signals are ON and to
the indicator lamp in the message center.
RIGHT TURN SIGNALS
Circuit Operation When the operator selects the right turn signal circuit L302 is connected to the Z1
ground circuit through the turn signal switch.
The combination flasher senses the position of the switch and supplies power to the L60 and L62
circuits.
Circuit L60 connects from the combination flasher to the right front turn signal lamp. Ground for the
lamp is supplied on circuit Z1 and terminates at the right cowl panel.
Circuit L62 connects from the combination flasher to the right rear turn signal lamp. Ground for the
lamp is supplied on circuit Z1 and terminates at the rear body ground. This circuit is also spliced
and provides an input to the Body Control Module (BCM) to indicate the turn signals are ON and to
the indicator lamp in the message center.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 7144
Turn Signal Flasher: Testing and Inspection
Electronic Combination Flasher Circuit
Electronic Combination Flasher With DRL Circuit
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through
a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This
circuit (L09) is the only power feed to the combination-flasher/ DRL.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 7145
Junction Block Terminal Call-Out
Junction Block Terminal Call-Out With DRL
The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal
Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems
with Ignition voltage if the vehicle is so equipped:
- Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically
5 mA of current while active.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 7146
Combination Flasher Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 7147
Combination Flasher Diagnosis (Part 2 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 7148
Combination Flasher Diagnosis With DRL (Part 1 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 7149
Combination Flasher Diagnosis With DRL (Part 2 Of 3)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 7150
Combination Flasher Diagnosis With DRL (Part 3 Of 3)
For diagnostic test procedures, refer to Combination Flasher Diagnosis tables.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 7151
Turn Signal Flasher: Service and Repair
Combination Flasher With/Without DRL Module
REMOVAL
Battery Negative Cable
1. Disconnect and isolate battery negative cable. 2. Remove lower steering column cover. Refer to
Instrument Panel and Systems for Replacement. 3. Remove knee blocker. Refer to Instrument
Panel and Systems for Removal and Installation. 4. Pull combination flasher from junction block.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Testing
and Inspection
Turn Signal Indicator: Testing and Inspection
BCM Controlled Components
Diagnostic trouble code information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the component level. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Testing and Inspection
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component
Information > Service and Repair
Turn Signal Bulb: Service and Repair
REMOVAL
1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and
back-up lamp to rear door opening trough. 3. Remove inner end of lamp from quarter panel. 4.
Disengage hook holding outer end of lamp to quarter panel opening. 5. Remove lamp from quarter
panel.
Tail, Stop, Turn Signal And Back-up Lamp Bulb
6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp.
Pull Bulb From Socket
8. Pull bulb from socket.
INSTALLATION
1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back
of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of
lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold
lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams
Multi-Function Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams
> Page 7162
Turn Signal Switch: Testing and Inspection
To test turn signal, headlamp beam select and optical horn portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Turn Signal - Multi-Function Switch Pin Numbers
2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the
above image for proper pin numbers and Turn
Signal Multi-Function Switch Test table.
TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between
Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams
> Page 7163
Turn Signal Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable.
3. Remove upper and lower steering column shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 7169
Heated Glass Element Relay: Diagrams
Junction Block
Rear Window Defogger Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component
Information > Description and Operation
Heated Glass Element Switch: Description and Operation
SYSTEM OPERATION
HVAC Control Panel/Rear Window Defogger Switch
The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when
the switch is activated. The switch energizes the timing circuit and activates the rear window
defogger relay. The relay controls the current to flow to the grids of the rear window defogger,
heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be
on for approximately 10 minutes or until the control switch or ignition is turned off.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
Junction Block -- Sheet 8w-12-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Page 7177
Heated Glass Element Relay: Diagrams
Junction Block
Rear Window Defogger Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Description and Operation
Heated Glass Element Switch: Description and Operation
SYSTEM OPERATION
HVAC Control Panel/Rear Window Defogger Switch
The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when
the switch is activated. The switch energizes the timing circuit and activates the rear window
defogger relay. The relay controls the current to flow to the grids of the rear window defogger,
heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be
on for approximately 10 minutes or until the control switch or ignition is turned off.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection
Power Window Switch: Testing and Inspection
1. Remove the desired switch to be tested from the door trim panel. Driver's side (master) or
passenger side. Refer to Power Window Switch and
Bezel Assembly Replacement.
Power Window Master Switch Connector
2. Using an ohmmeter, Test driver door switch for continuity as described.
*
MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS
11 AND 6
Passenger Door Power Window Switch
3. Test passenger door switch for continuity as described. 4. If the results are not OK, replace the
switch. The power window master switch has a Auto-Down feature. The switch is equipped with
two detent
positions when actuating the power window OPEN. The first detent position allows the window to
roll down and stop when the switch is released. The second detent position actuates an integral
express roll down relay that rolls the window down after the switch is released. When the express
down relay senses an amperage spike (motor pushing against down stop) in the feed circuit,
current is turned off to the motor. The AUTO feature can be cancelled by actuating the switch UP
or DOWN while window is in motion. Failure of the electronic switch to detect an amperage spike
will cause the switch to disconnect after approximately 11 seconds.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 7185
Power Window Switch: Service and Repair
Window Switch and Bezel Replacement The Power Window Switch is integral to the bezel. If
service to the switch is required, the complete bezel must be replaced. The Owe Door Lock Switch
is serviced separately and must be transferred to the new bezel.
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Open door, remove screw cover near
inside door release handle. 3. Remove two screws to Power Window Switch and Bezel Assembly
One under the screw cover removed in previous step and one to the rear of the
front door vent opening.
4. Pull out and up on bezel to release from door trim panel. 5. Disconnect two switch connectors. 6.
Remove two door lock switch retaining screws and remove switch from bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair
Front Door Window Motor: Service and Repair
WARNING: DO NOT HAVE ANY HANDS OR FINGERS IN AREA WHERE THEY CAN BE
PINCHED BY SMALL MOVEMENTS OF REGULATOR LINKAGE.
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel and sound
pad. 3. Tape the window in its existing position to remove its weight from the regulator system. 4.
Cut and remove the tie wrap at the window motor. Its no longer required. 5. Disconnect window
motor wire connector from door harness. 6. Remove screws and nuts holding window motor to the
inner panel. 7. Remove the motor from the door inner panel, let it hang from the cables. 8. With the
cables still attached to the failed motor, Install the replacement motor to the door inner panel.
Tighten down the screws and nuts to 3.4 to
4.5 Nm (30 to 40 in. lbs.) of torque.
9. Separate the failed motor from regulator by:
- Removing the drum cover plate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair > Page 7191
Power Window Motor Removal
- Lift the cable guide off the motor, the drum with cables, will be lifted off simultaneously.
CAUTION: Do not allow the drum to separate from the cable guide, by dropping drum or letting the
cables unwind.
INSTALLATION
1. Install the cable guide and drum into the replacement motor.
CAUTION: The drum may require a slight rotation to install onto the motor drive shaft. Rotate the
drum with the use of needle nose pliers or a similar tool. If, the drum does not align with the motor
shaft by a slight rotation,then, the glass should be lowered a small amount approximately 1 to 2
inches. The drum will rotate when the glass is lowered. Lowering the glass will require assistance
of a second person.
2. Install the replacement cover plate onto the replacement motor. Crimp toy tabs. 3. Connect the
wiring harness to the window motor connector. 4. Remove the tape holding the window in place
and test window operation. 5. Re-assemble remaining parts in reverse order as above.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection
Power Window Switch: Testing and Inspection
1. Remove the desired switch to be tested from the door trim panel. Driver's side (master) or
passenger side. Refer to Power Window Switch and
Bezel Assembly Replacement.
Power Window Master Switch Connector
2. Using an ohmmeter, Test driver door switch for continuity as described.
*
MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS
11 AND 6
Passenger Door Power Window Switch
3. Test passenger door switch for continuity as described. 4. If the results are not OK, replace the
switch. The power window master switch has a Auto-Down feature. The switch is equipped with
two detent
positions when actuating the power window OPEN. The first detent position allows the window to
roll down and stop when the switch is released. The second detent position actuates an integral
express roll down relay that rolls the window down after the switch is released. When the express
down relay senses an amperage spike (motor pushing against down stop) in the feed circuit,
current is turned off to the motor. The AUTO feature can be cancelled by actuating the switch UP
or DOWN while window is in motion. Failure of the electronic switch to detect an amperage spike
will cause the switch to disconnect after approximately 11 seconds.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 7195
Power Window Switch: Service and Repair
Window Switch and Bezel Replacement The Power Window Switch is integral to the bezel. If
service to the switch is required, the complete bezel must be replaced. The Owe Door Lock Switch
is serviced separately and must be transferred to the new bezel.
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the battery negative cable. 2. Open door, remove screw cover near
inside door release handle. 3. Remove two screws to Power Window Switch and Bezel Assembly
One under the screw cover removed in previous step and one to the rear of the
front door vent opening.
4. Pull out and up on bezel to release from door trim panel. 5. Disconnect two switch connectors. 6.
Remove two door lock switch retaining screws and remove switch from bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and
Repair > Front Door Window Regulator
Window Regulator: Service and Repair Front Door Window Regulator
FRONT DOOR WINDOW REGULATOR
REMOVAL
1. Remove door trim panel and sound shield. 2. Remove door glass retaining clips and allow glass
to rest on bottom of door. 3. Disconnect wire connector from power window motor, if equipped.
4. Loosen screws attaching front and rear window guide rails to inner door panel. 5. Remove screw
heads on guide rails from key hole slots in inner door panel. 6. Loosen screws attaching regulator
to inner door panel. 7. Remove regulator from inner door panel.
Front Door Power Window Regulator
8. Extract rear guide rail through inner door panel rear access hole. 9. Extract front guide rail
through front access hole.
INSTALLATION
1. Insert front guide rail through front access hole. 2. Insert rear guide rail through rear access hole.
3. Place window regulator in position on inner door panel. 4. Place screw heads on guide rails in
position through key hole slots in inner door panel. 5. Tighten screws to attach front and rear guide
rails to inner door panel. 6. Connect wire connector into power window motor, if equipped. 7. Install
door glass. 8. Verify door glass alignment and operation. 9. Install sound shield and door trim
panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and
Repair > Front Door Window Regulator > Page 7200
Window Regulator: Service and Repair Power Window Regulator Replacement
REMOVAL
1. Remove door trim panel and water shield. 2. Remove door glass retaining clips and allow glass
to rest on bottom of door. 3. If equipped, disengage wire connector from power window motor.
Front Door Glass Window Lift Guides
4. Loosen screws holding front and rear window lift guides to inner door panel. 5. Separate screw
heads on lift guides from key hole slots in inner door panel. 6. Loosen screws holding regulator to
inner door panel.
7. Remove regulator from inner door panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and
Repair > Front Door Window Regulator > Page 7201
Front Door Window Regulator
8. Extract rear lift guide through inner door panel access hole. 9. Extract front lift guide through
access hole.
INSTALLATION
1. Insert front lift guide through access hole.
Front Door Window Regulator
2. Insert rear lift guide through access hole. 3. Place window regulator in position on inner door
panel. 4. Place screw heads on guide rails in position through key hole slots in inner door panel. 5.
Tighten screws to hold regulator to inner door panel. 6. Place screw heads on lift guides in position
through key hole slots in inner door panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and
Repair > Front Door Window Regulator > Page 7202
Front Door Glass Window Lift Guides
7. Tighten screws to hold front and rear window lift guides to inner door panel. 8. If equipped,
engage wire connector into power window motor. 9. Install door glass.
10. Verify door glass alignment and operation. 11. Install water shield and door trim panel.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Service and
Repair
Window Seal: Service and Repair
Rear Glass Rubber Grommet
REMOVAL
1. Remove rear window wiper motor. Refer to Rear Window Wiper Motor Replacement. 2. Peel
wiper pivot seal grommet from rear glass.
Rear Glass Rubber Grommet
3. Remove grommets from vehicle.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations
Front Windshield Wiper
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations > Page 7211
Wiper Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Relay > Component Information > Locations
Wiper Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Relay > Component Information > Locations > Page 7215
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Relay > Component Information > Locations > Page 7216
Wiper Relay: Diagrams
Power Distribution Center
Wiper High/Low Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Relay > Component Information > Locations > Page 7217
Wiper On/Off Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Diagrams
Washer Fluid Level Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Testing and Inspection
Windshield Washer Switch: Testing and Inspection
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Fig.1 Wiper/Washer Switch Pin Call Out
Windshield Wiper and Washer / Multi-function Switch Test
2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper
and Washer / Multi-function Switch Test table.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Testing and Inspection > Page 7225
Windshield Washer Switch: Service and Repair
REMOVAL AND INSTALLATION
Refer to Turn Signal and Flashers, for Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams
Multi-Function Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Failed Park Switch
Wiper Switch: Testing and Inspection Failed Park Switch
If the wiper park switch has failed the windshield wipers will operate as follows: SWITCH OFF Wipers stop in current location regardless of the park signal. INTERMITTENT MODE - Wipers
operate at low speed for one or more extra wipes or continuously. LOW SPEED - Wipers operate
at low speed. HIGH SPEED - Wipers operate at high speed. PULSE WIPE - Wipers will not
operate. WIPE AFTER WASH - Wipers operate at low speed in any mode setting. Wipers operate
only while wash button is depressed with switch in OFF mode, wipers stop in mid-cycle when
button is released.
Wiper System Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 7231
Wiper System Diagnosis (Part 2 Of 2)
The windshield wiper park switch and circuit is monitored by the BCM. The park switch and circuit
can be tested using the Wiper System Diagnosis table.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 7232
Wiper Switch: Testing and Inspection Wiper Switch Test
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Fig.1 Wiper/Washer Switch Pin Call Out
Windshield Wiper and Washer / Multi-function Switch Test
2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper
and Washer / Multi-function Switch Test table.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Page 7233
Wiper Switch: Service and Repair
REMOVAL AND INSTALLATION
Refer to Turn Signal and Flashers, for Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
Diagrams
Washer Fluid Level Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Diagrams
Rear Washer Pump
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Service and Repair
Windshield Washer Reservoir: Service and Repair
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the negative battery cable. 2. Hoist and support vehicle on safety stands.
3. Remove right front wheel. 4. Remove front wheelhouse splash shield.
Negative Battery Cable
5. Disconnect connectors from the front windshield and rear window washer pumps, the fluid level
sensor, and the rear washer hose. 6. If washer bottle has fluid in it place a suitable drain pan under
the hose connections.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Service and Repair > Page 7243
Front Washer Hose
7. Disconnect front washer hose at front wiper unit in the engine compartment. The front hose will
be removed with the bottle. 8. Allow washer bottle to drain. 9. Remove screws holding washer
bottle to front fender support and remove bottle.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection
Windshield Washer Switch: Testing and Inspection
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Fig.1 Wiper/Washer Switch Pin Call Out
Windshield Wiper and Washer / Multi-function Switch Test
2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper
and Washer / Multi-function Switch Test table.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Page 7247
Windshield Washer Switch: Service and Repair
REMOVAL AND INSTALLATION
Refer to Turn Signal and Flashers, for Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments
Wiper Arm: Adjustments
1. Verify wiper blade element condition and wiper arm spring tension. Run wipers in low speed
mode while applying water to the windshield.
Observe the wiper blade that is chattering or skipping across the windshield. If the wiper element is
not rolling over when the wiper direction reverses, align the wiper arm. The extension bar portion of
the wiper arm must be twisted in the proper direction to allow the wiper element to roll over when
the direction reverses.
2. Place two small adjustable wrenches placed 50 mm (2 in.) apart on the wiper arm extension rod.
3. Twist the extension rod slightly in the opposite direction that the element is laying on the
windshield while holding the wrench closest to the pivot
stationary.
4. Repeat step Step 1, and align as necessary until wiper stops chattering and wipes the
windshield clear.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Arm
Wiper Arm: Service and Repair Wiper Arm
CAUTION: The Driver side wiper arm must be parked above the passenger side. Failure to do so
will result in damage to the arms, blades, or system.
REMOVAL
1. Disengage the clip holding outside end of the wiper arm pivot cover to the wiper arm. 2. Lift the
arm cap upward. 3. Remove the nut holding wiper arm to the wiper pivot.
Wiper Arm Removal
4. Using a suitable two jaw puller, separate the wiper arm from the wiper pivot.
INSTALLATION
1. Verify that the wiper motor and linkage are in the park position.
Wiper Arm Adjustment
2. Place the wiper arm in position over the wiper pivot. Refer to Alignment. 3. Install the nut to hold
the wiper arm to the wiper pivot. Tighten nut to 35 Nm (26 ft. lbs.). 4. Push the arm cap cover
down. 5. Engage clip to the hold outside end of wiper arm pivot cover to the wiper arm.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Arm > Page 7253
Wiper Arm: Service and Repair Rear Wiper Arm
REMOVAL
1. Lift and hold wiper blade away from rear window. 2. Lift lock holding wiper arm to wiper pivot
upward. 3. Allow wiper arm to rest against lock.
Rear Wiper Arm
4. Pull wiper from pivot.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak
Windshield
Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield
NUMBER: 23-014-06
GROUP: Body
DATE: March 8, 2006
SUBJECT: Windshield Wiper Blade/Element Maintenance
MODELS: All
All All Chrysler Group Vehicles
DISCUSSION:
Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the
environmental conditions vehicles can be operated in, a film can build up on both the windshield
and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in
some instances, a chattering condition as the wipers blades travel across the windshield.
Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A
simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that
is required.
If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper
blades/elements is obvious, the following steps should be performed:
1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n
04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n
04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield.
2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with
MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth,
paper towel or sponge.
3. Return the wiper blades to their normal operating position and function the washer system. If the
wiper blades/elements are not streaking the windshield or chattering, replacing the blade
assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times.
If the wipe pattern is still objectionable, replace the wiper blades/elements.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or
Streak Windshield
Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield
NUMBER: 23-014-06
GROUP: Body
DATE: March 8, 2006
SUBJECT: Windshield Wiper Blade/Element Maintenance
MODELS: All
All All Chrysler Group Vehicles
DISCUSSION:
Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the
environmental conditions vehicles can be operated in, a film can build up on both the windshield
and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in
some instances, a chattering condition as the wipers blades travel across the windshield.
Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A
simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that
is required.
If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper
blades/elements is obvious, the following steps should be performed:
1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n
04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n
04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield.
2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with
MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth,
paper towel or sponge.
3. Return the wiper blades to their normal operating position and function the washer system. If the
wiper blades/elements are not streaking the windshield or chattering, replacing the blade
assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times.
If the wipe pattern is still objectionable, replace the wiper blades/elements.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair >
Cleaning and Inspection
Wiper Blade: Service and Repair Cleaning and Inspection
Wiper blades exposed to the weather for a long period of time tend to lose their wiping
effectiveness. Periodic cleaning of the wiper blade is recommended to remove the accumulation of
salt and road grime. The wiper blades, arms and windshield should be cleaned with a sponge or
cloth and a mild detergent or nonabrasive cleaner. If the wiper blades continue to streak or smear,
they should be replaced. The wiper blade should run smoothly across the windshield in both
directions. The wiper blade should slightly roll over center when the blade reverses direction. A
wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the
blade to skip or chatter across the windshield. If the wiper blades are new and the wiper arm spring
tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not rolling over
center. If this condition exists, refer to the Wiper Arm Alignment.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair >
Cleaning and Inspection > Page 7269
Wiper Blade: Service and Repair Rear Wiper Blade
REMOVAL
1. Lift wiper blade away from rear window.
Rear Wiper Arm
2. Release latch holding blade to wiper arm. 3. Remove blade from wiper arm.
INSTALLATION
For installation reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair >
Cleaning and Inspection > Page 7270
Wiper Blade: Service and Repair Rear Wiper Blade Element Replacement
REMOVAL AND INSTALLATION
Refer to Windshield Wiper Blade Element Replacement.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair >
Cleaning and Inspection > Page 7271
Wiper Blade: Service and Repair Wiper Blade
REMOVAL
1. Lift the wiper arm away from windshield.
Windshield Wiper Blade Element
2. Disengage the release tab holding the wiper blade to the wiper arm and remove the wiper blade
from the wiper arm. 3. Remove the wiper blade from the wiper arm.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair >
Cleaning and Inspection > Page 7272
Wiper Blade: Service and Repair Wiper Blade Element
REMOVAL
Windshield Wiper Blade Element
1. Disengage the release tab holding the wiper blade to the wiper arm and remove the wiper blade
from the wiper arm.
Windshield Wiper Blade Element
2. Disengage clip holding the wiper element to wiper blade. 3. Pull the element from the claws on
the wiper blade.
INSTALLATION
Wiper Blade And Element
1. Insert the element vertebra into claw at the open end of the wiper blade and through each claw
location along the blade. 2. Engage clip to hold wiper element to wiper blade. 3. Test wiper
effectiveness using washer mode and align if necessary.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations
Front Windshield Wiper
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations >
Page 7276
Wiper Module
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations
Rear Wiper Motor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 7280
Rear Wiper Motor
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Rear Wiper Motor Replacement
Wiper Motor: Service and Repair Rear Wiper Motor Replacement
REMOVAL
Negative Battery Cable
1. Disconnect and isolate the negative battery cable. 2. Remove rear wiper arm. Refer to Rear
Wiper Arm Replacement. 3. Open liftgate. 4. Remove liftgate trim panel. 5. Disconnect wire
connector from rear wiper motor.
Rear Window Wiper Motor
6. Remove screws holding rear wiper motor to liftgate. 7. Remove wiper motor from liftgate.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Rear Wiper Motor Replacement > Page 7283
Wiper Motor: Service and Repair Replacement
REMOVAL
1. Remove wiper unit from vehicle. Refer to Wiper Unit Replacement. 2. Remove wiper linkage and
motor mount plate from wiper unit.
Wiper Motor Connector
3. Disconnect wire connectors from back of wiper motor. 4. Remove wiper linkage from motor
crank. Do NOT remove crank from motor.
Wiper Motor Crank
Wiper Motor
5. Remove bolts holding wiper motor to mount plate and remove motor.
INSTALLATION
1. Place wiper unit on a suitable work surface. 2. Place wiper motor in position on mount plate.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Rear Wiper Motor Replacement > Page 7284
3. Install bolts to hold wiper motor to mount plate. 4. Install wiper linkage and motor mount plate
into wiper unit. 5. Connect wire connectors to wiper motor.
Wiper Unit Wire Connector
6. Place the wiper unit into engine compartment and connect wiper unit wire connector to engine
wire harness. 7. Operate wiper motor and verify that the wiper motor parks when wiper switch is
turned OFF.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and
Repair
Wiper Motor Linkage: Service and Repair
REMOVAL
1. Remove the windshield wiper unit from vehicle. Refer to Wiper Unit Replacement. 2. Place the
wiper unit on a suitable work surface. 3. Remove nuts holding the cowl cover brackets to the wiper
unit. 4. Remove cowl cover brackets from the wiper unit.
Wiper Linkage
5. Remove nuts holding linkage and motor mount plate to the wiper unit. 6. Remove the wiper
linkage from the wiper unit.
Wiper Motor Connector
7. Disconnect the wire connectors from back of the wiper motor.
INSTALLATION
For installation, reverse the above procedure.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations
Wiper Relay: Locations
Battery Negative Cable
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7291
Power Distribution Center -- Sheet 8w-10-2
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7292
Wiper Relay: Diagrams
Power Distribution Center
Wiper High/Low Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 7293
Wiper On/Off Relay
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams
Multi-Function Switch
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and
Inspection > Failed Park Switch
Wiper Switch: Testing and Inspection Failed Park Switch
If the wiper park switch has failed the windshield wipers will operate as follows: SWITCH OFF Wipers stop in current location regardless of the park signal. INTERMITTENT MODE - Wipers
operate at low speed for one or more extra wipes or continuously. LOW SPEED - Wipers operate
at low speed. HIGH SPEED - Wipers operate at high speed. PULSE WIPE - Wipers will not
operate. WIPE AFTER WASH - Wipers operate at low speed in any mode setting. Wipers operate
only while wash button is depressed with switch in OFF mode, wipers stop in mid-cycle when
button is released.
Wiper System Diagnosis (Part 1 Of 2)
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and
Inspection > Failed Park Switch > Page 7299
Wiper System Diagnosis (Part 2 Of 2)
The windshield wiper park switch and circuit is monitored by the BCM. The park switch and circuit
can be tested using the Wiper System Diagnosis table.
Dodge Caravan Fwd Workshop Manual (V6-3.8L VIN L (1999))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and
Inspection > Failed Park Switch > Page 7300
Wiper Switch: Testing and Inspection Wiper Switch Test
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Fig.1 Wiper/Washer Switch Pin Call Out
Windshield Wiper and Washer / Multi-function Switch Test
2. Using an ohmmeter check continuity reading between switch pins. Refer to the Windshield Wiper
and Washer / Multi-function Switch Test table.